Power management integrated circuit

ABSTRACT

A device may include a rectifier circuit providing a rectified DC signal, a rechargeable energy-storage element, and a power-management integrated circuit (PMIC). The PMIC may include a charging circuit for the rechargeable energy-storage element; a current-sensing circuit that measures a current provided by the rectified DC signal; a programmable current limit; a voltage-sensing circuit that measures a voltage on the rechargeable energy-storage element; and a controller that regulates the current provided to a DC output of the PMIC. the DC output of the PMIC may be regulated based at least in part on the current provided by the rectified DC signal; the programmable current limit; and the voltage on the rechargeable energy-storage element. The DC output of the PMIC may provide energy to a plurality of other energy-consuming subsystems on the device and to the charging circuit for the rechargeable energy-storage element.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.15/680,632, filed Aug. 18, 2017, which is incorporated here byreference.

TECHNICAL FIELD

This patent specification relates to systems, methods, and relatedcomputer program products for the monitoring and control ofenergy-consuming systems or other resource-consuming systems. Moreparticularly, this specification relates to monitoring and recoverableprotection of circuitry in smart-home devices, such as thermostats.

BACKGROUND

During the installation or subsequent upgrade of an HVAC system, thereare occasions when wires may be incorrectly connected to variouscomponents of the HVAC system, including an electronic thermostat. Whenwires are incorrectly connected to a thermostat, there is thepossibility for a short circuit to be created that if not accounted forcould result in permanent damage to either the thermostat, the HVACwiring and/or other HVAC system components. In order to protect againstsuch conditions, the electronic thermostat can include one or more fusesthat are designed to blow under the increased current of a short circuitcondition. However, blown fuses are problematic from support andcustomer satisfaction viewpoint. The problem of blown fuses can beparticularly problematic for thermostats during installation, andproblems can be difficult to diagnose and remedy.

Additionally, switching circuitry in a thermostat can also be used toactuate, or activate, HVAC functions, such as air conditioning, heating,and/or fan operations. When a common (“C”) wire is not available, modernadvanced thermostats may steal power from HVAC call signal wires atlevels low enough to not interfere with normal HVAC functions, but highenough to charge an energy storage element, such as a rechargeablebattery or large capacitor. Thus, modern thermostat designers shoulddesign switching circuitry that can both protect the thermostat fromvoltage/current anomalies while still enabling power stealingfunctionality.

BRIEF SUMMARY

In some embodiments, a smart-home device may include an energy-storageelement that stores energy that is harvested from an environmentalsystem, a power wire connector and a return wire connector, and a solidstate relay (SSR) switching integrated circuit (IC). The SSR switchingIC may include one or more switching elements configured to operate in afirst operating state in which the one or more switching elements createa connection between the power wire connector and the return wireconnector, and a second operating state in which the one or moreswitching elements interrupt the connection between the power wireconnector and the return wire connector. The SSR switching IC may alsoinclude a digital control circuit that controls the one or moreswitching elements. The digital control circuit may be configured tocause the one or more switching elements to operate in the firstoperating state to activate an environmental function of theenvironmental system, and determine that an electrical property of theenergy-storage element has dropped below a first threshold while the oneor more switching elements operate in the first operating state. Thedigital control circuit may also be configured to, in response todetermining that the electrical property of the energy-storage elementhas dropped below the first threshold, cause the one or more switchingelements to operate in the second operating state. The digital controlcircuit may be additionally configured to harvest energy from theenvironmental system while the one or more switching elements operate inthe second operating state, determine that a first time has elapsedsince the one or more switching elements began operating in the secondoperating state, and, in response to determining that the first time haselapsed since the one or more switching elements began operating in thesecond operating state, cause the one or more switching elements tooperate in the first operating state.

In any embodiment, one or more of the following features may beimplemented in any combination and without limitation. The first timemay be short enough in duration that execution of the environmentalfunction of the environmental system is not interrupted. The SSRswitching IC may further include a monitoring circuit that receives asignal indicating an electrical characteristic of the energy-storageelement. The SSR switching IC may further include one or more referencescoupled to one or more comparators, where the one or more comparatorsmay determine how the electrical characteristic of the energy-storageelement compares to the one or more references. The digital controlcircuit may be further configured to, while harvesting energy from theenvironmental system when the one or more switching elements operate inthe second operating state, monitor the electrical property of theenergy-storage element to determine if the electrical property of theenergy-storage element has risen above a second threshold. The one ormore switching elements may include a pair of field-effect transistors(FETs). The SSR switching IC may further include a serial bus interface.Causing the one or more switching elements to operate in the firstoperating state to activate the environmental function of theenvironmental system may occur in response to receiving a command toactivate the environmental function, where the command may be receivedfrom a smart-home-device processor that is not part of the SSR switchingIC via the serial bus interface. The smart-home device may include athermostat, and the environmental system may include a heating,ventilation, and air conditioning (HVAC) system. The SSR switching ICmay be packaged in a physical chip that is separate from theenergy-storage element.

In some embodiments, a smart-home device may include a rectifier circuitproviding a rectified DC signal, a rechargeable energy-storage element,and a power-management integrated circuit (PMIC). The PMIC may include acharging circuit for the rechargeable energy-storage element, acurrent-sensing circuit that measures a current provided by therectified DC signal, a programmable current limit, a voltage-sensingcircuit that measures a voltage on the rechargeable energy-storageelement, and a controller that regulates the current provided to a DCoutput of the PMIC. The current output may be regulated based at leastin part on the current provided by the rectified DC signal a DC output,the programmable current limit, and the voltage on the rechargeableenergy-storage element. The DC output of the PMIC may provide energy to(i) a plurality of other energy-consuming systems on the smart-homedevice, and (ii) the charging circuit for the rechargeableenergy-storage element.

In any embodiment, one or more of the following features may beimplemented in any combination and without limitation. The DC output ofthe PMIC may be coupled through an inductor to a storage capacitor. Thecontroller may regulate the current provided to a DC output bycontrolling a timing of a voltage applied to a gate of a transistor thatis connected in series between the rectified DC signal and the DCoutput. The timing of the voltage applied to the gate of the transistormay cause the transistor to act as a buck converter for the DC output.The controller may include a pulse-width modulated (PWM) controller thatregulates a pulse width of the voltage applied to the gate of thetransistor. The controller may include a pulse-frequency modulation(PFM) controller or a constant on-time (COT) controller. The pluralityof other energy-consuming systems on the smart-home device includes aplurality of DC/DC voltage converters. The controller may cause the DCoutput to provide at least a minimum voltage when the voltage on therechargeable energy-storage element falls below the minimum voltage. Theminimum voltage may correspond to a minimum required voltage of at leastone of the plurality of other energy-consuming systems on the smart-homedevice. The controller may regulate the voltage of the DC output to beone voltage drop higher than a desired voltage on the rechargeableenergy-storage element.

In some embodiments, a smart-home device may include a solid state relay(SSR) switching integrated circuit (IC). SSR switching IC may includeone or more switching elements configured to open and close a connectionbetween a power wire and a return wire of an environmental system; avoltage sensor that measures a voltage across the one or more switchingelements; a current sensor that measures a current through the one ormore switching elements; and a temperature sensor that measures atemperature near the one or more switching elements. The smart-homedevice may also include a wireless communication device thatperiodically receives voltage, current, and temperature data originatingfrom the SSR switching IC and transmits the voltage, current, andtemperature data to a device management server. The device managementserver may receive batches of voltage, current, and temperature datafrom a plurality of smart-home devices.

In some embodiments, a method of monitoring and correcting electricalanomalies in a smart-home device may include opening or closing aconnection between a power wire and a return wire of an environmentalsystem using one or more switching elements of a solid state relay (SSR)switching integrated circuit (IC) on the smart-home device. The methodmay also include measuring a voltage across the one or more switchingelements using a voltage sensor of the SSR switching IC, measuring acurrent through the one or more switching elements using a currentsensor of the SSR switching IC, and measuring a temperature near the oneor more switching elements using a temperature sensor of the SSRswitching IC. The method may additionally include transmitting voltage,current, and temperature data originating from the SSR switching IC to adevice management server using a wireless communication device of thesmart-home device. The device management server may receive batches ofvoltage, current, and temperature data from a plurality of smart-homedevices.

In any embodiment, one or more of the following features may beimplemented in any combination and without limitation. The SSR switchingIC further comprises a analog-to-digital converter (ADC) and amultiplexer, wherein outputs from the voltage sensor, the currentsensor, and the temperature sensor are individually selected by themultiplexer for conversion by the ADC. The SSR switching IC may furtherinclude a memory that stores at least 20 ms of voltage, current, andtemperature data. The smart-home device may further include a mainprocessor, where the SSR switching IC may periodically transfer thevoltage, current, and temperature data from the memory of the SSRswitching IC to the main processor, and the main processor mayperiodically transfer the voltage, current, and temperature data to thewireless communication device. The one or more switching elements may beconfigured to connect to a first transformer of the environmentalsystem. The SSR switching IC may further include second one or moreswitching elements configured to connect to a second transformer of theenvironmental system. The first transformer and the second transformermay be 180° out of phase. The SSR switching IC may further include athreshold detection circuit wherein the voltage, current, andtemperature data originating from the SSR switching IC is collected inresponse to a detected threshold violation. The voltage, current, andtemperature data may indicate an over-current or over-voltage event. Thewireless communication device may receive a software update from thedevice management server for operation of the SSR switching IC tocorrect the over-current or over-voltage event.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example of a smart home environment within whichone or more of the devices, methods, systems, services, and/or computerprogram products described further herein can be applicable.

FIG. 2 illustrates a network-level view of an extensible devices andservices platform with which the smart home of FIG. 1 can be integrated,according to some embodiments.

FIG. 3 illustrates an abstracted functional view of the extensibledevices and services platform of FIG. 2, according to some embodiments.

FIG. 4 illustrates a schematic diagram of an HVAC system, according tosome embodiments.

FIG. 5 illustrates a front view of a thermostat having a roundedexterior appearance including one or more sensors for detectingoccupancy and/or users, according to some embodiments.

FIG. 6 illustrates a side view of a thermostat having a rounded exteriorappearance including one or more sensors for detecting occupancy and/orusers, according to some embodiments.

FIG. 7 illustrates a block diagram illustrating circuitry within athermostat, according to some embodiments.

FIG. 8 illustrates a custom power management integrated circuit (PMIC).

FIG. 9 illustrates a simplified block diagram of a smart-home thermostatusing the PMIC of FIG. 8.

FIG. 10A illustrates one specific embodiment of a smart-home thermostatusing the PMIC of FIG. 8 to manage the power and battery chargingfunctions.

FIG. 10B illustrates an alternate embodiment of the PMIC of FIG. 8 withan internal current limit and buck converter circuit.

FIG. 10C illustrates an internal current limit and buck convertercircuit using an internal FET rather than an external diode.

FIG. 11 illustrates an embodiment of a smart-home hazard detector thatalso uses the PMIC of FIG. 8.

FIG. 12 illustrates a block diagram of a FET switch used to control thefunctionality of the HVAC system.

FIG. 13A illustrates an embodiment of a solid state relay (SSR)switching integrated circuit (IC).

FIG. 13B illustrates a second embodiment of an SSR switching IC.

FIG. 14 illustrates a thermostat circuit architecture using the SSRswitching IC, according to some embodiments.

FIG. 15 illustrates a timing diagram using minimum and maximumthresholds to control power stealing intervals, according to someembodiments.

FIG. 16 illustrates a flowchart of a method for controlling powerstealing using a SSR switching IC with upper/lower voltage comparators,according to some embodiments.

FIG. 17 illustrates a timing diagram using a minimum threshold and atiming requirement to control power stealing intervals, according tosome embodiments.

FIG. 18 illustrates a flowchart of a method for controlling powerstealing using a SSR switching IC with a lower voltage comparator and atime interval, according to some embodiments.

FIG. 19 illustrates an SSR switching IC with two different, parallelsets of SSR circuits.

FIG. 20 illustrates a thermostat configuration that uses two SSRswitching ICs 1302 to interface with HVAC systems having multipletransformers, according to some embodiments.

FIG. 21 illustrates a block diagram of how telemetry data can be savedand recorded from each of the SSR circuits, according to someembodiments.

FIG. 22 illustrates a flowchart of a method for using telemetry datafrom an SSR switching IC to monitor performance, according to someembodiments.

FIG. 23 illustrates a flowchart of a method for triggering waveformsample storage using predetermined thresholds, according to someembodiments.

DETAILED DESCRIPTION The Smart-Home Environment

A detailed description of the inventive body of work is provided herein.While several embodiments are described, it should be understood thatthe inventive body of work is not limited to any one embodiment, butinstead encompasses numerous alternatives, modifications, andequivalents. In addition, while numerous specific details are set forthin the following description in order to provide a thoroughunderstanding of the inventive body of work, some embodiments can bepracticed without some or all of these details. Moreover, for thepurpose of clarity, certain technical material that is known in therelated art has not been described in detail in order to avoidunnecessarily obscuring the inventive body of work.

As used herein the term “HVAC” includes systems providing both heatingand cooling, heating only, cooling only, as well as systems that provideother occupant comfort and/or conditioning functionality such ashumidification, dehumidification and ventilation. Generally an HVACsystem is one of many possible environmental control systems that can beused in conjunction with the embodiments described herein. Otherenvironmental control systems may include security systems, sprinklermonitoring systems, smart home appliances, smart home environments,intercom systems, and so forth.

As used herein the terms power “harvesting,” “sharing” and “stealing”when referring to HVAC thermostats all refer to thermostats that aredesigned to derive power from the power transformer through theequipment load without using a direct or common wire source directlyfrom the transformer.

As used herein the term “residential” when referring to an HVAC systemmeans a type of HVAC system that is suitable to heat, cool and/orotherwise condition the interior of a building that is primarily used asa single family dwelling. An example of a cooling system that would beconsidered residential would have a cooling capacity of less than about5 tons of refrigeration (1 ton of refrigeration=12,000 Btu/h).

As used herein the term “light commercial” when referring to an HVACsystem means a type of HVAC system that is suitable to heat, cool and/orotherwise condition the interior of a building that is primarily usedfor commercial purposes, but is of a size and construction that aresidential HVAC system is considered suitable. An example of a coolingsystem that would be considered residential would have a coolingcapacity of less than about 5 tons of refrigeration.

As used herein the term “thermostat” means a device or system forregulating parameters such as temperature and/or humidity within atleast a part of an enclosure. The term “thermostat” may include acontrol unit for a heating and/or cooling system or a component part ofa heater or air conditioner. As used herein the term “thermostat” canalso refer generally to a versatile sensing and control unit (VSCU unit)that is configured and adapted to provide sophisticated, customized,energy-saving HVAC control functionality while at the same time beingvisually appealing, non-intimidating, elegant to behold, anddelightfully easy to use.

FIG. 1 illustrates an example of a smart home environment within whichone or more of the devices, methods, systems, services, and/or computerprogram products described further herein can be applicable. Thedepicted smart home environment includes a structure 150, which caninclude, e.g., a house, office building, garage, or mobile home. It willbe appreciated that devices can also be integrated into a smart homeenvironment that does not include an entire structure 150, such as anapartment, condominium, or office space. Further, the smart homeenvironment can control and/or be coupled to devices outside of theactual structure 150. Indeed, several devices in the smart homeenvironment need not physically be within the structure 150 at all. Forexample, a device controlling a pool heater or irrigation system can belocated outside of the structure 150.

The depicted structure 150 includes a plurality of rooms 152, separatedat least partly from each other via walls 154. The walls 154 can includeinterior walls or exterior walls. Each room can further include a floor156 and a ceiling 158. Devices can be mounted on, integrated with and/orsupported by a wall 154, floor or ceiling.

The smart home depicted in FIG. 1 includes a plurality of devices,including intelligent, multi-sensing, network-connected devices that canintegrate seamlessly with each other and/or with cloud-based serversystems to provide any of a variety of useful smart home objectives.One, more or each of the devices illustrated in the smart homeenvironment and/or in the figure can include one or more sensors, a userinterface, a power supply, a communications component, a modularity unitand intelligent software as described herein. Examples of devices areshown in FIG. 1.

An intelligent, multi-sensing, network-connected thermostat 102 candetect ambient climate characteristics (e.g., temperature and/orhumidity) and control a heating, ventilation and air-conditioning (HVAC)system 103. One or more intelligent, network-connected, multi-sensinghazard detection units 104 can detect the presence of a hazardoussubstance and/or a hazardous condition in the home environment (e.g.,smoke, fire, or carbon monoxide). One or more intelligent,multi-sensing, network-connected entryway interface devices 106, whichcan be termed a “smart doorbell”, can detect a person's approach to ordeparture from a location, control audible functionality, announce aperson's approach or departure via audio or visual means, or controlsettings on a security system (e.g., to activate or deactivate thesecurity system).

Each of a plurality of intelligent, multi-sensing, network-connectedwall light switches 108 can detect ambient lighting conditions, detectroom-occupancy states and control a power and/or dim state of one ormore lights. In some instances, light switches 108 can further oralternatively control a power state or speed of a fan, such as a ceilingfan. Each of a plurality of intelligent, multi-sensing,network-connected wall plug interfaces 110 can detect occupancy of aroom or enclosure and control supply of power to one or more wall plugs(e.g., such that power is not supplied to the plug if nobody is athome). The smart home may further include a plurality of intelligent,multi-sensing, network-connected appliances 112, such as refrigerators,stoves and/or ovens, televisions, washers, dryers, lights (inside and/oroutside the structure 150), stereos, intercom systems, garage-dooropeners, floor fans, ceiling fans, whole-house fans, wall airconditioners, pool heaters 114, irrigation systems 116, security systems(including security system components such as cameras, motion detectorsand window/door sensors), and so forth. While descriptions of FIG. 1 canidentify specific sensors and functionalities associated with specificdevices, it will be appreciated that any of a variety of sensors andfunctionalities (such as those described throughout the specification)can be integrated into the device.

In addition to containing processing and sensing capabilities, each ofthe devices 102, 104, 106, 108, 110, 112, 114 and 116 can be capable ofdata communications and information sharing with any other of thedevices 102, 104, 106, 108, 110, 112, 114 and 116, as well as to anycloud server or any other device that is network-connected anywhere inthe world. The devices can send and receive communications via any of avariety of custom or standard wireless protocols (Wi-Fi, ZigBee,6LoWPAN, Thread, Bluetooth, BLE, HomeKit Accessory Protocol (HAP),Weave, etc.) and/or any of a variety of custom or standard wiredprotocols (CAT6 Ethernet, HomePlug, etc.). Each of the devices 102, 104,106, 108, 110, 112, 114 and 116 may also be capable of receiving voicecommands or other voice-based inputs from a user, such as the GoogleHome® interface. The wall plug interfaces 110 can serve as wireless orwired repeaters, and/or can function as bridges between (i) devicesplugged into AC outlets and communicating using Homeplug or other powerline protocol, and (ii) devices that not plugged into AC outlets.

For example, a first device can communicate with a second device via awireless router 160. A device can further communicate with remotedevices via a connection to a network, such as the Internet 162. Throughthe Internet 162, the device can communicate with a central server or acloud-computing system 164. The central server or cloud-computing system164 can be associated with a manufacturer, support entity or serviceprovider associated with the device. For one embodiment, a user may beable to contact customer support using a device itself rather thanneeding to use other communication means such as a telephone orInternet-connected computer. Further, software updates can beautomatically sent from the central server or cloud-computing system 164to devices (e.g., when available, when purchased, or at routineintervals).

By virtue of network connectivity, one or more of the smart-home devicesof FIG. 1 can further allow a user to interact with the device even ifthe user is not proximate to the device. For example, a user cancommunicate with a device using a computer (e.g., a desktop computer,laptop computer, or tablet) or other portable electronic device (e.g., asmartphone). A webpage or app can be configured to receivecommunications from the user and control the device based on thecommunications and/or to present information about the device'soperation to the user. For example, the user can view a current setpointtemperature for a device and adjust it using a computer. The user can bein the structure during this remote communication or outside thestructure.

The smart home also can include a variety of non-communicating legacyappliances 140, such as old conventional washer/dryers, refrigerators,and the like which can be controlled, albeit coarsely (ON/OFF), byvirtue of the wall plug interfaces 110. The smart home can furtherinclude a variety of partially communicating legacy appliances 142, suchas IR-controlled wall air conditioners or other IR-controlled devices,which can be controlled by IR signals provided by the hazard detectionunits 104 or the light switches 108.

FIG. 2 illustrates a network-level view of an extensible devices andservices platform with which the smart home of FIG. 1 can be integrated,according to some embodiments. Each of the intelligent,network-connected devices from FIG. 1 can communicate with one or moreremote central servers or cloud computing systems 164. The communicationcan be enabled by establishing connection to the Internet 162 eitherdirectly (for example, using 3G/4G connectivity to a wireless carrier),though a hubbed network (which can be scheme ranging from a simplewireless router, for example, up to and including an intelligent,dedicated whole-home control node), or through any combination thereof.

The central server or cloud-computing system 164 can collect operationdata 202 from the smart home devices. For example, the devices canroutinely transmit operation data or can transmit operation data inspecific instances (e.g., when requesting customer support). The centralserver or cloud-computing architecture 164 can further provide one ormore services 204. The services 204 can include, e.g., software update,customer support, sensor data collection/logging, remote access, remoteor distributed control, or use suggestions (e.g., based on collectedoperation data 204 to improve performance, reduce utility cost, etc.).Data associated with the services 204 can be stored at the centralserver or cloud-computing system 164 and the central server orcloud-computing system 164 can retrieve and transmit the data at anappropriate time (e.g., at regular intervals, upon receiving requestfrom a user, etc.).

One salient feature of the described extensible devices and servicesplatform, as illustrated in FIG. 2, is a processing engines 206, whichcan be concentrated at a single server or distributed among severaldifferent computing entities without limitation. Processing engines 206can include engines configured to receive data from a set of devices(e.g., via the Internet or a hubbed network), to index the data, toanalyze the data and/or to generate statistics based on the analysis oras part of the analysis. The analyzed data can be stored as derived data208. Results of the analysis or statistics can thereafter be transmittedback to a device providing ops data used to derive the results, to otherdevices, to a server providing a webpage to a user of the device, or toother non-device entities. For example, use statistics, use statisticsrelative to use of other devices, use patterns, and/or statisticssummarizing sensor readings can be transmitted. The results orstatistics can be provided via the Internet 162. In this manner,processing engines 206 can be configured and programmed to derive avariety of useful information from the operational data obtained fromthe smart home. A single server can include one or more engines.

The derived data can be highly beneficial at a variety of differentgranularities for a variety of useful purposes, ranging from explicitprogrammed control of the devices on a per-home, per-neighborhood, orper-region basis (for example, demand-response programs for electricalutilities), to the generation of inferential abstractions that canassist on a per-home basis (for example, an inference can be drawn thatthe homeowner has left for vacation and so security detection equipmentcan be put on heightened sensitivity), to the generation of statisticsand associated inferential abstractions that can be used for governmentor charitable purposes. For example, processing engines 206 can generatestatistics about device usage across a population of devices and sendthe statistics to device users, service providers or other entities(e.g., that have requested or may have provided monetary compensationfor the statistics). As specific illustrations, statistics can betransmitted to charities 222, governmental entities 224 (e.g., the Foodand Drug Administration or the Environmental Protection Agency),academic institutions 226 (e.g., university researchers), businesses 228(e.g., providing device warranties or service to related equipment), orutility companies 230. These entities can use the data to form programsto reduce energy usage, to preemptively service faulty equipment, toprepare for high service demands, to track past service performance,etc., or to perform any of a variety of beneficial functions or tasksnow known or hereinafter developed.

FIG. 3 illustrates an abstracted functional view of the extensibledevices and services platform of FIG. 2, with particular reference tothe processing engine 206 as well as the devices of the smart home. Eventhough the devices situated in the smart home will have an endlessvariety of different individual capabilities and limitations, they canall be thought of as sharing common characteristics in that each of themis a data consumer 302 (DC), a data source 304 (DS), a services consumer306 (SC), and a services source 308 (SS). Advantageously, in addition toproviding the essential control information needed for the devices toachieve their local and immediate objectives, the extensible devices andservices platform can also be configured to harness the large amount ofdata that is flowing out of these devices. In addition to enhancing oroptimizing the actual operation of the devices themselves with respectto their immediate functions, the extensible devices and servicesplatform can also be directed to “repurposing” that data in a variety ofautomated, extensible, flexible, and/or scalable ways to achieve avariety of useful objectives. These objectives may be predefined oradaptively identified based on, e.g., usage patterns, device efficiency,and/or user input (e.g., requesting specific functionality).

For example, FIG. 3 shows processing engine 206 as including a number ofparadigms 310. Processing engine 206 can include a managed servicesparadigm 310 a that monitors and manages primary or secondary devicefunctions. The device functions can include ensuring proper operation ofa device given user inputs, estimating that (e.g., and responding to) anintruder is or is attempting to be in a dwelling, detecting a failure ofequipment coupled to the device (e.g., a light bulb having burned out),implementing or otherwise responding to energy demand response events,or alerting a user of a current or predicted future event orcharacteristic. Processing engine 206 can further include anadvertising/communication paradigm 310 b that estimates characteristics(e.g., demographic information), desires and/or products of interest ofa user based on device usage. Services, promotions, products or upgradescan then be offered or automatically provided to the user. Processingengine 206 can further include a social paradigm 310 c that usesinformation from a social network, provides information to a socialnetwork (for example, based on device usage), processes data associatedwith user and/or device interactions with the social network platform.For example, a user's status as reported to their trusted contacts onthe social network could be updated to indicate when they are home basedon light detection, security system inactivation or device usagedetectors. As another example, a user may be able to share device-usagestatistics with other users. Processing engine 206 can include achallenges/rules/compliance/rewards paradigm 310 d that informs a userof challenges, rules, compliance regulations and/or rewards and/or thatuses operation data to determine whether a challenge has been met, arule or regulation has been complied with and/or a reward has beenearned. The challenges, rules or regulations can relate to efforts toconserve energy, to live safely (e.g., reducing exposure to toxins orcarcinogens), to conserve money and/or equipment life, to improvehealth, etc.

Processing engine can integrate or otherwise utilize extrinsicinformation 316 from extrinsic sources to improve the functioning of oneor more processing paradigms. Extrinsic information 316 can be used tointerpret operational data received from a device, to determine acharacteristic of the environment near the device (e.g., outside astructure that the device is enclosed in), to determine services orproducts available to the user, to identify a social network orsocial-network information, to determine contact information of entities(e.g., public-service entities such as an emergency-response team, thepolice or a hospital) near the device, etc., to identify statistical orenvironmental conditions, trends or other information associated with ahome or neighborhood, and so forth.

An extraordinary range and variety of benefits can be brought about by,and fit within the scope of, the described extensible devices andservices platform, ranging from the ordinary to the profound. Thus, inone “ordinary” example, each bedroom of the smart home can be providedwith a smoke/fire/CO alarm that includes an occupancy sensor, whereinthe occupancy sensor is also capable of inferring (e.g., by virtue ofmotion detection, facial recognition, audible sound patterns, etc.)whether the occupant is asleep or awake. If a serious fire event issensed, the remote security/monitoring service or fire department isadvised of how many occupants there are in each bedroom, and whetherthose occupants are still asleep (or immobile) or whether they haveproperly evacuated the bedroom. While this is, of course, a veryadvantageous capability accommodated by the described extensible devicesand services platform, there can be substantially more “profound”examples that can truly illustrate the potential of a larger“intelligence” that can be made available. By way of perhaps a more“profound” example, the same data bedroom occupancy data that is beingused for fire safety can also be “repurposed” by the processing engine206 in the context of a social paradigm of neighborhood childdevelopment and education. Thus, for example, the same bedroom occupancyand motion data discussed in the “ordinary” example can be collected andmade available for processing (properly anonymized) in which the sleeppatterns of schoolchildren in a particular ZIP code can be identifiedand tracked. Localized variations in the sleeping patterns of theschoolchildren may be identified and correlated, for example, todifferent nutrition programs in local schools.

FIG. 4 is a schematic diagram of an HVAC system, according to someembodiments. HVAC system 103 provides heating, cooling, ventilation,and/or air handling for an enclosure, such as structure 150 depicted inFIG. 1. System 103 depicts a forced air type heating and cooling system,although according to other embodiments, other types of HVAC systemscould be used such as radiant heat based systems, heat-pump basedsystems, and others.

For carrying out the heating function, heating coils or elements 442within air handler 440 provide a source of heat using electricity or gasvia line 436. Cool air is drawn from the enclosure via return air duct446 through filter 470, using fan 438 and is heated through the heatingcoils or elements 442. The heated air flows back into the enclosure atone or more locations via supply air duct system 452 and supply airregisters such as register 450. In cooling, an outside compressor 430passes a refrigerant gas through a set of heat exchanger coils and thenthrough an expansion valve. The gas then goes through line 432 to thecooling coils or evaporator coils 434 in the air handler 440 where itexpands, cools and cools the air being circulated via fan 438. Ahumidifier 454 may optionally be included in various embodiments thatreturns moisture to the air before it passes through duct system 452.Although not shown in FIG. 4, alternate embodiments of HVAC system 103may have other functionality such as venting air to and from theoutside, one or more dampers to control airflow within the duct system452 and an emergency heating unit. Overall operation of HVAC system 103is selectively actuated by control electronics 412 communicating withthermostat 102 over control wires 448.

The Smart-Home Thermostat

FIG. 5 illustrates a front view of a thermostat having a roundedexterior appearance and including one or more sensors for detectingenvironmental conditions, such as occupancy and/or users, temperature,ambient light, humidity, and so forth. FIG. 6 illustrates a bottomelevation view of the same thermostat 102. Unlike many prior artthermostats, thermostat 102 has a simple and elegant design. Moreover,user interaction with thermostat 102 is facilitated and greatly enhancedover known conventional thermostats. The thermostat 102 includes controlcircuitry and is electrically connected to an HVAC system 103, such asis shown in FIGS. 1-4. Thermostat 102 is wall mountable, is circular inshape, and has an outer rotatable ring 512 for receiving user input.Thermostat 102 has a large convex rounded front face lying inside theouter rotatable ring 512. According to some embodiments, thermostat 102is approximately 84 mm in diameter and protrudes from the wall, whenwall mounted, by 30 mm. The outer rotatable ring 512 allows the user tomake adjustments, such as selecting a new setpoint temperature. Forexample, by rotating the outer ring 512 clockwise, the real-time (i.e.currently active) setpoint temperature can be increased, and by rotatingthe outer ring 512 counter-clockwise, the real-time setpoint temperaturecan be decreased.

The front face of the thermostat 102 comprises a cover 514 thataccording to some embodiments is polycarbonate, and a lens 510 having anouter shape that matches the contours of the curved outer front face ofthe thermostat 102. According to some embodiments, Fresnel lens elementsmay be formed on the interior surface of the lens 510 such that they arenot obviously visible by viewing the exterior of the thermostat 102.Behind the lens 510 is a passive infrared (PIR) sensor 550 for detectingoccupancy, a temperature sensor that is thermally coupled to the lens510, and a multi-channel thermopile for detecting occupancy, userapproaches, and motion signatures. The Fresnel lens elements of the lens510 are made from a high-density polyethylene (HDPE) that has aninfrared transmission range appropriate for sensitivity to human bodies.The lens 510 may also include thin sections that allow a near-fieldproximity sensor 552, such as a multi-channel thermopile, and atemperature sensor to “see-through” the lens 510 with minimalinterference from the polyethylene. As shown in FIGS. 5-6, the frontedge of the outer rotatable ring 512, cover 514, and lens 510 are shapedsuch that they together form an integrated convex rounded front facethat has a common outward arc or spherical shape arcing outward.

Although being formed from a single lens-like piece of material such aspolycarbonate, the cover 514 has two different regions or portionsincluding an outer portion 514 o and a central portion 514 i. Accordingto some embodiments, the cover 514 is darkened around the outer portion514 o, but leaves the central portion 514 i visibly clear so as tofacilitate viewing of an electronic display 516 disposed underneath.According to some embodiments, the cover 514 acts as a lens that tendsto magnify the information being displayed in electronic display 516 tousers. According to some embodiments the central electronic display 516is a dot-matrix layout (i.e. individually addressable) such thatarbitrary shapes can be generated. According to some embodiments,electronic display 516 is a backlit, color liquid crystal display (LCD).An example of information displayed on the electronic display 516 isillustrated in FIG. 5, and includes central numerals 520 that arerepresentative of a current setpoint temperature. The thermostat 102 maybe constructed such that the electronic display 516 is at a fixedorientation and does not rotate with the outer rotatable ring 512. Forsome embodiments, the cover 514 and lens 510 also remain at a fixedorientation and do not rotate with the outer ring 512. In alternativeembodiments, the cover 514 and/or the lens 510 can rotate with the outerrotatable ring 512. According to one embodiment in which the diameter ofthe thermostat 102 is about 84 mm, the diameter of the electronicdisplay 516 is about 54 mm. According to some embodiments the curvedshape of the front surface of thermostat 102, which is made up of thecover 514, the lens 510 and the front facing portion of the ring 512, isspherical, and matches a sphere having a radius of between 100 mm and180 mm. According to some embodiments, the radius of the spherical shapeof the thermostat front is about 156 mm.

Motion sensing with PIR sensor 550 as well as other techniques can beused in the detection and/or prediction of occupancy. According to someembodiments, occupancy information is used in generating an effectiveand efficient scheduled program. A second near-field proximity sensor552 is also provided to detect an approaching user. The near-fieldproximity sensor 552 can be used to detect proximity in the range of upto 10-15 feet. The PIR sensor 550 and/or the near-field proximity sensor552 can detect user presence such that the thermostat 102 can initiate“waking up” and/or providing adaptive screen displays that are based onuser motion/position when the user is approaching the thermostat andprior to the user touching the thermostat. Such use of proximity sensingis useful for enhancing the user experience by being “ready” forinteraction as soon as, or very soon after the user is ready to interactwith the thermostat. Further, the wake-up-on-proximity functionalityalso allows for energy savings within the thermostat by “sleeping” whenno user interaction is taking place or about to take place.

According to some embodiments, the thermostat 102 may be controlled byat least two types of user input, the first being a rotation of theouter rotatable ring 512 as shown in FIG. 5, and the second being aninward push on head unit 540 until an audible and/or tactile “click”occurs. For such embodiments, the head unit 540 is an assembly thatincludes the outer ring 512, the cover 514, the electronic display 516,and the lens 510. When pressed inwardly by the user, the head unit 540travels inwardly by a small amount, such as 0.5 mm, against an interiorswitch (not shown), and then springably travels back out when the inwardpressure is released, providing a tactile “click” along with acorresponding audible clicking sound. Thus, for the embodiment of FIGS.5-6, an inward click can be achieved by direct pressing on the outerrotatable ring 512 itself, or by indirect pressing of the outerrotatable ring 512 by virtue of providing inward pressure on the cover514, the lens 510, or by various combinations thereof. For otherembodiments, the thermostat 102 can be mechanically configured such thatonly the outer ring 512 travels inwardly for the inward click input,while the cover 514 and lens 510 remain motionless.

FIG. 6 illustrates a right side elevation view of the thermostat 102.According to some embodiments, the thermostat 102 includes a processingsystem 560, display driver 564 and a wireless communications system 566.The processing system 560 is adapted to cause the display driver 564 anddisplay 516 to display information to the user, and to receive userinput via the outer rotatable ring 512. The processing system 560,according to some embodiments, is capable of carrying out the governanceof the operation of thermostat 102 including various user interfacefeatures. The processing system 560 is further programmed and configuredto carry out other operations, such as maintaining and updating athermodynamic model for the enclosure in which the HVAC system isinstalled. According to some embodiments, a wireless communicationssystem 566 is used to communicate with devices such as personalcomputers, other thermostats or HVAC system components, smart phones,local home wireless networks, routers, gateways, home appliances,security systems, hazard detectors, remote thermostat managementservers, distributed sensors and/or sensor systems, and other componentsit the modern smart-home environment. Such communications may includepeer-to-peer communications, communications through one or more serverslocated on a private network, or and/or communications through acloud-based service.

According to some embodiments, the thermostat 102 includes a head unit540 and a backplate (or wall dock) 542. Head unit 540 of thermostat 102is slidably mountable onto back plate 542 and slidably detachabletherefrom. According to some embodiments the connection of the head unit540 to backplate 542 can be accomplished using magnets, bayonet, latchesand catches, tabs, and/or ribs with matching indentations, or simplyfriction on mating portions of the head unit 540 and backplate 542. Alsoshown in FIG. 5A is a rechargeable battery 522 that is recharged usingrecharging circuitry 524 that uses power from backplate that is eitherobtained via power harvesting (also referred to as power stealing and/orpower sharing) from the HVAC system control circuit(s) or from a commonwire, if available. According to some embodiments, the rechargeablebattery 522 may include a single cell lithium-ion battery, or alithium-polymer battery.

FIG. 7 illustrates a power management and power harvesting system for asmart thermostat, according to some embodiments. FIG. 7 showsconnections to common HVAC wiring, such as a W (heat call relay wire); Y(cooling call relay wire); Y2 (second stage cooling call relay wire); Rh(heat call relay power); Rc (cooling call relay power); G (fan callrelay wire); O/B (heat pump call relay wire); AUX (auxiliary call relaywire); HUM (humidifier call relay wire); and C (common wire). Thethermostat 102 comprises a plurality of FET switches 706 used forcarrying out the essential thermostat operations of connecting or“shorting” one or more selected pairs of HVAC wires together accordingto the desired HVAC operation. The operation of each of the FET switches706 is controlled by a secondary processor 708 which can comprise, forexample, an STM32L 32-bit ultra-low power ARM-based microprocessoravailable from ST Microelectronics.

Thermostat 102 further comprises powering circuitry 710 that comprisescomponents contained on both the backplate 542 and head unit 540.Generally speaking, it is the purpose of powering circuitry 710 toextract electrical operating power from the HVAC wires and convert thatpower into a usable form for the many electrically-driven components ofthe thermostat 102. Thermostat 102 further comprises insertion sensingcomponents 712 configured to provide automated mechanical and electricalsensing regarding the HVAC wires that are inserted into the thermostat102. Thermostat 102 further comprises a relatively high-power primaryprocessor 732, such as an AM3703 Sitara ARM microprocessor availablefrom Texas Instruments, the i.MX 6SoloX ARM microprocessor availablefrom NXP, and/or the i.MX 6UltraLite also available from NXP, thatprovides the main general governance of the operation of the thermostat102. Thermostat 102 further comprises environmental sensors 734/738(e.g., temperature sensors, humidity sensors, active IR motion sensors,passive IR motion sensors, multi-channel thermopiles, ambient visiblelight sensors, accelerometers, ambient sound sensors,ultrasonic/infrasonic sound sensors, microwave sensors, GPS sensors,etc.), as well as other components 736 (e.g., electronic display devicesand circuitry, user interface devices and circuitry, wiredcommunications circuitry, wireless communications circuitry, etc.) thatare operatively coupled to the primary processor 732 and/or secondaryprocessor 708 and collectively configured to provide the functionalitiesdescribed in the instant disclosure.

The insertion sensing components 712 include a plurality of HVAC wiringconnectors 684, each containing an internal springable mechanicalassembly that, responsive to the mechanical insertion of a physical wirethereinto, will mechanically cause an opening or closing of one or morededicated electrical switches associated therewith. With respect to theHVAC wiring connectors 684 that are dedicated to the C, W, Y, Rc, and Rhterminals, those dedicated electrical switches are, in turn, networkedtogether in a manner that yields the results that are illustrated inFIG. 7 by the blocks 716 and 718. The output of block 716, which isprovided at a node 719, is dictated solely by virtue of the particularcombination of C, W, and Y connectors into which wires have beenmechanically inserted in accordance with the following rules: if a wireis inserted into the C connector, then the node 719 becomes the C noderegardless of whether there are any wires inserted into the Y or Wconnectors; if no wire is inserted into the C connector and a wire isinserted into the Y connector, then the node 719 becomes the Y noderegardless of whether there is a wire inserted into the W connector; andif no wire is inserted into either of the C or Y connectors, then thenode 719 becomes the W node. Block 718 is shown as being coupled to theinternal sensing components 712 by virtue of double lines termed“mechanical causation,” for the purpose of denoting its operation, whichis either to short the Rc and Rh nodes together or not to short the Rcand Rh nodes together. Whether the block 718 will short, or not short,the Rc and Rh nodes together is dictated solely by virtue of theparticular combination of Rc and Rh connectors into which wires havebeen mechanically inserted. Block 718 will keep the Rc and Rh nodesshorted together, unless wires have been inserted into both the Rc andRh connectors, in which case the block 718 will not short the Rc and Rhnodes together because a two-HVAC-transformer system is present. Foreach of the respective wiring connectors 684, the insertion sensingcircuitry 712 is also configured to provide at least two signals to thesecondary processor 708, the first being a simple “open” or “short”signal that corresponds to the mechanical insertion of a wire, and thesecond being a voltage or other level signal that represents a sensedelectrical signal at that terminal. The first and second electricalsignals for each of the respective wiring terminals 684 canadvantageously be used as a basis for basic “sanity checking” to helpdetect and avoid erroneous wiring conditions.

Basic operation of each of the FET switches 706 is achieved by virtue ofa respective control signal (e.g., W-CTL, Y-CTL) provided by thesecondary processor 708 that causes the corresponding FET switch 706 to“connect” or “short” its respective HVAC lead inputs for an ON controlsignal, and that causes the corresponding FET switch 706 to “disconnect”or “leave open” or “open up” its respective HVAC lead inputs for an“OFF” control signal. By virtue of the above-described operation ofblock 718, it is automatically the case that for single-transformersystems having only an “R” wire (rather than separate Rc and Rh wires aswould be present for two-transformer systems), that “R” wire can beinserted into either of the Rc or Rh terminals, and the Rh-Rc nodes willbe automatically shorted to form a single “R” node, as needed for properoperation. In contrast, for dual-transformer systems, the insertion oftwo separate wires into the respective Rc and Rh terminals will causethe Rh-Rc nodes to remain disconnected to maintain two separate Rc andRh nodes, as needed for proper operation.

Referring now to the powering circuitry 710 in FIG. 7, provided is aconfiguration that automatically adapts to the powering situationpresented to the thermostat 102 at the time of installation andthereafter. The powering circuitry 710 comprises a full-wave bridgerectifier 720, a storage and waveform-smoothing bridge output capacitor722 (which can be, for example, on the order of 30 microfarads), a buckregulator circuit system 724, a power-and-battery (PAB) regulationcircuit 728, and a rechargeable lithium-ion battery 730. In conjunctionwith other control circuitry including backplate power managementcircuitry 727, head unit power management circuitry 729, and thesecondary processor 708, the powering circuitry 710 is configured andadapted to have the characteristics and functionality describedhereinbelow.

By virtue of the configuration illustrated in FIG. 7, when there is a“C” wire presented upon installation, the powering circuitry 710operates as a relatively high-powered, rechargeable-battery-assistedAC-to-DC converting power supply. When there is not a “C” wirepresented, the powering circuitry 710 operates as a power-stealing,rechargeable-battery-assisted AC-to-DC converting power supply. Asillustrated in FIG. 7, the powering circuitry 710 generally serves toprovide the voltage Vcc MAIN that is used by the various electricalcomponents of the thermostat 102, and that in one embodiment willusually be about 3.7V-3.95V. The general purpose of powering circuitry710 is to convert the 24 VAC presented between the input leads 719 and717 to a steady DC voltage output at the Vcc MAIN node to supply thethermostat electrical power load.

Operation of the powering circuitry 710 for the case in which the “C”wire is present is now described. When the 24 VAC input voltage betweennodes 719 and 717 is rectified by the full-wave bridge rectifier 720, aDC voltage at node 723 is present across the bridge output capacitor722, and this DC voltage is converted by the buck regulator system 724to a relatively steady voltage, such as 4.4 volts, at node 725, whichprovides an input current IBP to the power-and-battery (PAB) regulationcircuit 728.

The secondary processor 708 controls the operation of the poweringcircuitry 710 at least by virtue of control leads leading between thesecondary processor 708 and the PAB regulation circuit 728, which forone embodiment can include an LTC4085-4 chip available from LinearTechnologies Corporation. The LTC4085-4 is a USB power manager andLi-Ion/Polymer battery charger originally designed for portablebattery-powered applications. The PAB regulation circuit 728 providesthe ability for the secondary processor 708 to specify a maximum valueIBP(max) for the input current IBP. The PAB regulation circuit 728 isconfigured to keep the input current at or below IBP(max), while alsoproviding a steady output voltage Vcc, such as 4.0 volts, while alsoproviding an output current Icc that is sufficient to satisfy thethermostat electrical power load, while also tending to the charging ofthe rechargeable battery 730 as needed when excess power is available,and while also tending to the proper discharging of the rechargeablebattery 730 as needed when additional power (beyond what can be providedat the maximum input current IBP(max)) is needed to satisfy thethermostat electrical power load.

Operation of the powering circuitry 710 for the case in which the “C”wire is not present is now described. As used herein, “inactive powerstealing” refers to the power stealing that is performed during periodsin which there is no active call in place based on the lead from whichpower is being stolen. As used herein, “active power stealing” refers tothe power stealing that is performed during periods in which there is anactive call in place based on the lead from which power is being stolen.

During inactive power stealing, power is stolen from between, forexample, the “Y” wire that appears at node 719 and the Rc lead thatappears at node 717. There will be a 24 VAC HVAC transformer voltagepresent across nodes 719/717 when no cooling call is in place (i.e.,when the Y-Rc FET switch is open). For one embodiment, the maximumcurrent IBP(max) is set to a relatively modest value, such as 20 mA, forthe case of inactive power stealing. Assuming a voltage of about 4.4volts at node 725, this corresponds to a maximum output power from thebuck regulator system 724 of about 88 mW. This power level of 88 mW hasbeen found to not accidentally trip the HVAC system into an “on” statedue to the current following through the call relay coil. During thistime period, the PAB regulator 728 operates to discharge the battery 730during any periods of operation in which the instantaneous thermostatelectrical power load rises above 88 mW, and to recharge the battery (ifneeded) when the instantaneous thermostat electrical power load dropsbelow 88 mW. The thermostat 700 is configured such that the averagepower consumption is well below 88 mW, and indeed for some embodimentsis even below 10 mW on a long-term time average.

Operation of the powering circuitry 710 for “active power stealing” isnow described. During an active heating/cooling call, it is necessaryfor current to be flowing through the HVAC call relay coil sufficient tomaintain the HVAC call relay in a “tripped” or ON state at all timesduring the active heating/cooling call. The secondary processor 708 isconfigured by virtue of circuitry denoted “PS MOD” to turn, for example,the Y-Rc FET switch OFF for small periods of time during the activecooling call, wherein the periods of time are small enough such that thecooling call relay does not “un-trip” into an OFF state, but wherein theperiods of time are long enough to allow inrush of current into thebridge rectifier 720 to keep the bridge output capacitor 722 to areasonably acceptable operating level. For one embodiment, this isachieved in a closed-loop fashion in which the secondary processor 708monitors the voltage VBR at node 723 and actuates the signal Y-CTL asnecessary to keep the bridge output capacitor 722 charged. According toone embodiment, it has been found advantageous to introduce a delayperiod, such as 60-90 seconds, following the instantiation of an activeheating/cooling cycle before instantiating the active power stealingprocess. This delay period has been found useful in allowing manyreal-world HVAC systems to reach a kind of “quiescent” operating statein which they will be much less likely to accidentally un-trip away fromthe active cooling cycle due to active power stealing operation of thethermostat 102. According to another embodiment, it has been foundfurther advantageous to introduce another delay period, such as 60-90seconds, following the termination of an active cooling cycle beforeinstantiating the inactive power stealing process. This delay period haslikewise been found useful in allowing the various HVAC systems to reacha quiescent state in which accidental tripping back into an activecooling cycle is avoided.

Power Management Integrated Circuit

In FIG. 7 above, the powering circuitry 710 is primarily configured toperform a number of different functions. For example, the poweringcircuitry 710 is configured to receive power from the HVAC system,either through a C wire or through power stealing from another HVACwire, and convert that power to a steady DC voltage using the full-wavebridge rectifier 720, the waveform-smoothing bridge output capacitor722, and the buck regulator circuit system 724. The power-and-battery(PAB) regulation circuit 728 is configured to accept the DC voltage fromthe buck regulator circuit system 724 and provide a Vcc Main outputvoltage to charge the rechargeable lithium-ion battery 730 or otherenergy-storage component. The backplate power management circuitry 727,the head unit power management circuitry 729, and a feedback circuit 780may be comprised of discrete, individual components on the thermostatcircuit board. In conjunction with the secondary processor 708, thepowering circuitry 710 regulates the opening/closing of the FET switches706 during power stealing intervals such that the normal operation ofthe HVAC system is not disturbed.

One possible disadvantage of using individual components as laid out inFIG. 7 is the stacking of tolerances. Because each component is likelymanufactured by different suppliers, the tolerances of each componentmay vary within the manufacturing specifications of the supplier. Whilethe tolerances of individual components (e.g., resistors, capacitors,diodes, etc.) may be small, when these tolerances are stacked togetherin an integrated circuit board like that of the smart-home thermostat,the overall tolerance of the system may vary greatly. This can affectthe efficiency with which power is harvested from the HVAC system, andcan affect the reliability of the powering circuitry 710, even when allof the components are all manufactured by the same provider.Additionally, building the powering circuitry 710 from individual,discrete components can be costly both in terms of assembly time andcomponent cost. Using discrete components on the circuit board alsoleads to quiescent current inefficiencies as many basic functions areduplicated, such as power-on-reset, analog references, digital controlblocks, and so forth.

To address these and many other issues, FIG. 8 illustrates a custompower management integrated circuit (PMIC) 802 that has been designedspecifically to increase the efficiency and reliability of the poweringcircuitry 710 for the smart-home thermostat. In some embodiments, thePMIC comprises a low-power single-chip power management IC that can beused in any battery-powered portable device. The PMIC 802 includes threelow-current consumption buck converters 804 and three low drop-outregulators (LDOs) 806 that can provide outputs of variousvoltages/currents as illustrated in FIG. 8. The PMIC 802 also includes apair of light-emitting diode (LED) drivers 808, a number of generalpurpose input/outputs (GPIOs) 810, a real-time clock (RTC) 812, a 32 kHzcrystal oscillator 814, a high-accuracy voltage reference VREF 816 foruse with an external analog-to-digital controller (ADC), a 10-bitsuccessive approximation register (SAR) ADC 818 that can be used with abattery temperature monitor, a battery charger 820 with scalable chargecurrents, a digitally programmable current limit 822, an I²Ccommunication interface, and a number of other systems that provide thefunctionality needed to replace much of the powering circuitry 710 fromFIG. 7.

The unique combination of functions in the PMIC 802 offers a singlesolution for many of the power management functions required by asmart-home thermostat or other smart-home devices. By packaging thesefunctions into a single integrated circuit, the overall cost of thepower management system can be reduced. Additionally, because thetolerances can be tightly controlled throughout the integrated circuitmanufacturing process, the PMIC 802 is not necessarily susceptible tothe same types of tolerance stacking issues that would otherwiseaccompany isolated, discrete components on a circuit board of asmart-home device. Integrating various circuit functions into a singleIC as described in the embodiments herein can reduce quiescent currentby sharing central functions (e.g., power-on-reset, analog references,digital control blocks, etc.).

To illustrate how the PMIC 802 can be used to replace some of thepowering circuitry 710 from FIG. 7, FIG. 9 illustrates a simplifiedblock diagram of a smart-home thermostat using the PMIC 802. For reasonsof clarity, some of the systems 804-822 of the PMIC 802 in FIG. 8 havebeen combined into single blocks in FIG. 9. Additionally, some of thesesystems, HVAC connections, and other circuitry from FIG. 7 have beenomitted for clarity. First, the buck regulator circuit system 724continues to provide a steady voltage (e.g., 4.4 V) at node 725. Thecurrent IBP may be received by the digitally programmable current limit822 of the PMIC 802. As described above in relation to FIG. 7, thedigitally programmable current limit 822 can replace the function of thePAB regulation circuit 728 to limit the amount of current drawn from theHVAC system. The current IBP may be used internally by the PMIC 802 topower the battery charger 820 to charge the rechargeable battery 730.The current IBP may also provide power to a main system supply thatreplaces the backplate power management circuitry 727 and head unitpower management circuitry 729 that previously provided voltage rails tothe internal systems of the smart-home thermostat. For example, powerrails can be provided by the PMIC 802 buck converters and LDOs to theprimary processor 732, the user interface and radios 736, the head unitenvironmental sensors 734, the backplate environmental sensors 738, theHVAC switches 706, and/or the secondary processor 708.

The PMIC 802 can communicate with the secondary processor 708 via acommunication bus, such as an I²C bus. This allows the secondaryprocessor 708 to adjust the operation of the PMIC 802 dynamically duringthe operation of the smart-home thermostat. For example, the secondaryprocessor 708 can cause the PMIC 802 to change the digitallyprogrammable current limit 822 during operation. In some embodiments, alink between the digital control of the PMIC 802 and the buck regulatorcircuit system 724 can be established, such that the secondary processor708 can cause the PMIC 802 to change the voltage/current that isprovided to the PMIC 802 from the buck regulator circuit system 724. Forexample, different HVAC systems may be able to provide more or lesscurrent before inadvertently tripping the HVAC call relay. The digitalcontrol of the PMIC 802 can be used to adjust the current provided bythe buck regulator circuit system 724 in response to variations in HVACsystem types. In some embodiments, the digital control of the PMIC 802can also adjust the current provided during active versus inactive HVACcycles. The digital control of the PMIC 802 can also change the outputvoltages of the buck converters for dynamic voltage and frequencyscaling (DVFS) of the primary processor 732. Some embodiments may alsoallow the secondary processor 708 to enable/disable the LED drivers ofthe PMIC 802 over the communication bus.

FIG. 10A illustrates one specific embodiment of a smart-home thermostatusing the PMIC 802 to manage the power and battery charging functions.As described above, the buck regulator circuit system 724 can providepower to the battery charger, which in turn can charge the lithium-ionrechargeable battery 730. The buck converters 804 can be set to 1.2 V,1.8 V, and 3.3 V. Similarly, the LDOs 806 can be set to 1.8 V, 3.0 V,and 3.3 V. These rails can be provided as shown in FIG. 10A to thevarious systems on the smart-home thermostat, including an LCD userinterface driver 1002, a flash memory 1004, an SoC chip 1006, a memory1008, various sensors 1010, level shifters for the high-voltage switches1012, onboard radios 1012, and a number of LED indicators 1014.Additionally, some of the I/O pins can be dedicated as I²C bus lines tocommunicate with the secondary processor 708.

It is to be understood that the circuit connections in FIG. 10 arespecific to one embodiment of a smart-home thermostat. In otherembodiments, different combinations of the voltages/currents provided bythe buck converters 804 and the LDOs 806 may be used to power differentsystems, depending on the needs of the thermostat. While this particularembodiment is specific to a power-harvesting thermostat that limits thecurrent received from the HVAC system and charges the rechargeablebattery 730, other embodiments may eliminate the battery chargingfunctionality.

FIG. 10B illustrates an alternate embodiment of the PMIC 802 with aninternal current limit and buck converter circuit. This circuit canreplace some of the internal/external circuit elements of the PMIC 802in FIG. 9 to more efficiently regulate the current drawn from the HVACsystem, more efficiently charge the battery by tracking the voltageoutput with the battery voltage, and provide a reliable current limitbefore DC conversion/regulation takes place.

The DC current from either the full rectifier diode bridge 720 or fromthe buck regulator 724 can be received at the DC input pin 1054, and acurrent-limited output can be generated at Lx1 at pin 1055. Inembodiments where the DC input is received from the full rectifier diodebridge 720, the buck regulator 724 can be eliminated from the circuitboard design, and the DC input can be regulated and current-limitedentirely by the top half of the circuit in FIG. 10B. The current sensecircuit 1056 senses the amount of current being received from the DCinput pin 1054. The current limit DAC 1058 stores a digitalrepresentation of a current limit programmed into the PMIC 802. Thiscurrent limit replaces the current limit set by the LTC 4085 chip (728)in FIG. 7.

The controller 1060 can receive the output from the current sense 1056and the output from the current limit DAC 1058 and use the differencebetween those two outputs to regulate the operation of the FET 1064 tothereby limit the current until the output of the current sense 1056 isapproximately equal to the output of the current limit DAC 1058. Ineffect, this moves the current regulation from the output of the buckregulator 724 in FIG. 7 to the PMIC 802. Recall that one purpose of thecurrent limit is to prevent the HVAC system from triggering during powerstealing. By moving the current limit function in front of the DCregulation in the circuit, the current can be effectively limited beforeany DC conversion takes place, thus minimizing the chance that the DCconversion could cause the HVAC system to inadvertently trigger.Additionally, moving the current limit function to the input of the buckconversion stage reduces one step in the tolerance stack-up describedabove, and it allows for greater overall power transfer during buckconversion.

To limit the current, the controller 1060 can regulate the gate voltageapplied to the FET 1064. Specifically, the controller 1016 can controlthe timing of voltages applied to the gate of the FET 1064 such thatswitching the FET 1064 on and off will operate like a buck converter. Insome embodiments, the controller 1060 may be a pulse-width modulated(PWM) controller that regulates the pulse width based on the differencebetween the output of the current sense 1056 and the current limit DAC1058. In some embodiments, the controller 1060 may be a pulse-frequencymodulation (PFM) controller or a constant on-time (COT) controller. Insome embodiments, the controller 1060 can regulate the average currentbased on this difference.

An external diode 1068 may be added at the Lx1 output on pin 1055.However, because the buck converter is internal to the PMIC 802, theexternal diode 1068 may also be moved to be internal to the PMIC 802 aswell. In some embodiments, the external diode 1068 may be replaced by aninternal FET that is connected to ground with the gate voltagecontrolled by the controller 1060. FIG. 10C illustrates an internalcurrent limit and buck converter circuit using an internal FET 1069rather than an external diode 1068. An inductor 1070 may also beprovided at the output between the Lx1 pin 1055 and the VSYS capacitor1072. The value of the inductor may be in the range of 10-470 μH. TheVSYS capacitor 1072 may be used to stabilize the output from thecurrent-limited buck converter inside the PMIC 802. In cases where theDC input at pin 1054 comes directly from the rectifier bridge 720, thevoltage on the VSYS capacitor 1072 may be the highest voltage relativeto all of the other power converters in the thermostat.

The PMIC 802 may use the voltage on the VSYS capacitor 1072 to power therest of the voltage regulators in the system described above. It shouldbe noted that this configuration increases the efficiency of the overallpower system dramatically because one of the regulators has beenremoved. For example, the buck regulator 724 and the LTC 728 in FIG. 7can be replaced by the PMIC circuit in FIG. 10B such that the Vcc Mainin FIG. 7 becomes the voltage on the VSYS capacitor 1072 in FIG. 10B. Asa further example, the digitally programmable current limit 822, themain supply, and the buck regulator 724 in FIG. 9 can be replaced by thecircuitry described thus far in FIG. 10B. The VSYS capacitor 1072 canthen provide the energy for the power management unit, the other buckconverters, the LDOs, etc., on the PMIC 802 that are described above inFIG. 8.

The bottom portion of the circuit in FIG. 10B forms a linear batterycharger. The voltage on the VSYS may be provided to the battery 730through an internal FET 1075. An external FET 1074 may be used in caseswhere the system desires a lower resistance between the battery 730 andthe VSYS rail than what can be otherwise provided by the internal FET1075. The external FET 1074 is optional, and may only be needed todischarge the battery 730. The controller 1060 can regulate the voltageon the VSYS capacitor 1072 to be one voltage drop (e.g. 200-300 mV)higher than the desired voltage on the battery 730. When the battery ischarging, the voltage level on the VSYS capacitor 1072 can be lowered tobe just above the voltage on the battery 730 (e.g., within 500 mV). Itshould be noted that allowing VSYS to drop can also make the internalregulators of the PMIC more efficient. As the charge on the battery 730increases, the controller 1060 can increase the voltage on the VSYScapacitor 1072 to track with the battery voltage as it is charged.

In order to allow the VSYS capacitor 1072 voltage to track with thevoltage of battery 730, a feedback loop is provided to thecurrent-limiting circuit. Specifically, the VBAT sense input to the PMIC802 can be fed back into a battery voltage tracking circuit 1050. Inother embodiments, the signal on the VBAT sense pin can be internallyconnected to the signal on the VBAT pin, making the VBAT sense pinoptional in some designs. The benefit of a dedicated VBAT sense pin isto reduce the impedance from the battery 730 to the internal sensingcircuit. Such impedance sources might include the battery connector,traces on the circuit board, wire bond impedance into the IC package,and/or pads and metallization on the IC. The battery voltage trackingcircuit 1050 can perform at least two functions. First, it can provide aminimum output voltage—independent of the actual battery voltage—that isrequired by the other regulators in the PMIC. This prevents a lowbattery voltage from causing the internal voltage rails to sag when VSYSis lowered when charging a drained battery. For example, if the internalmemory requires 3.3 V, then the battery voltage tracking circuit 1050would provide a minimum voltage of 3.3 V regardless of the batteryvoltage. Second, the battery voltage tracking circuit 1050 tracks thevoltage on the battery 730 and compares the battery voltage to theminimum voltage. After this comparison, the battery voltage trackingcircuit 1050 provides the higher of the two voltages to the controller1060 as a target voltage for VSYS. Conceptually, a converter needs aclosed current loop and a closed voltage loop. The current sense 1056effectively closes the current loop, while the battery voltage trackingcircuit 1050 and FB pin from the VSYS capacitor 1072 effectively closesthe voltage loop.

Block 1062 represents a circuit that provides reverse currentprotection. In some situations, the voltage on the VSYS capacitor 1072can be supplied by the battery 730. When the voltage on the battery 730is high and the voltage on the DC input 1054 is lower than the battery,the VSYS capacitor 1072 can receive voltage from the battery 730. Thiscould cause current to flow backwards through the DC input 1054, whichwould cause leakage and possibly cause the device to erroneously try toregulate the reverse current. Block 1060 can be used to prevent thisreverse-current effect from occurring. In some embodiments, block 1062can be implemented using back-to-back NFETs such that the current flowcan be turned off in both directions. The back-to-back NFETs can be usedfor high voltage applications. In other embodiments, one of the NFETscan be replaced with a bulk switch that determines the direction of thecurrent flow. The solution may be advantageous because the bulk switchis typically half the size of the NFET in the silicon die. Otherembodiments can also use a PFET.

The lower portion of the circuit in FIG. 10B illustrates a linearbattery charger that receives voltage from VSYS. The controller 1080 cancontrol the voltage on FET 1075 to provide a battery charging voltage atVBAT. The Optional Sense (Opt Sense) input can provide the controller1080 with a voltage measurement after the external FET voltage drop. Insome embodiments, the Opt Sense, the VBAT, and the VBAT sense pins canall be combined into a single pin externally and separated internally.In some embodiments, the Ext GDRV and the Opt Sense pins can be omittedentirely or combined to stay separate from the VBAT pin'ssourcing/sinking of current. In some embodiments, it is possible tocombine VBAT and both sense pins and then separate these signalsinternal to the IC, but this may affect the performance of the circuit.

The versatility of the PMIC 802 also allows for its advantageousintegration into other types of smart-home devices in addition to thesmart home thermostat described above. For example, FIG. 11 illustratesan embodiment of a smart-home hazard detector that also uses the PMIC802 to provide voltage rails of various levels to different systems inthe smart-home hazard detector. Generally, a hazard detector will notneed to harvest power from an external environmental system. Therefore,in the embodiment of FIG. 11 the charger of the PMIC is not connected toan external rechargeable battery. Instead, the power from the inrushlimiter can be provided directly to the PMIC 802 through the VSYS pin.From this, the buck converters 804 can be set to appropriate levels,such as 0.9 V-1.1 V, 1.8 V, and 3.3 V, and the LDOs 806 can be set to1.8 V, 3.0 V, and 1.8 V. These voltage rails can be used to providepower to various memories 1102, SoCs/MCUs 1104, an audio codec 1106,various sensors 1108, onboard radios 1110, LED indicators 1112, and soforth.

In some embodiments, smart home devices, such as the hazard detector ofFIG. 11 may also include rechargeable batteries that are maintained forbackup purposes in the case of emergency or power-outage scenarios. Inthese types of devices, the PMIC 802 can charge the rechargeable batteryusing the connections depicted in FIG. 10. In other embodiments, powermay be externally provided from a reliable source, and the PMIC 802 canbe connected to such a source as depicted in FIG. 11 while alsomaintaining a rechargeable battery as in FIG. 10. One having skill inthe art will be able to use the connections to various device systemsdepicted in FIGS. 10-11 to provide similar voltage rails to other typesof smart-home devices. For example, the PMIC 802 may be used in devicesthat are part of a wireless home security system, including videocameras, speakers, microphones, door sensors, and so forth. The PMIC 802may also be used in any of the other smart-home systems described abovein relation to FIG. 1. The versatility of the PMIC 802 may also allow itto be used in other portable electronic devices, such as smart phones,PDAs, and other portable computing devices.

FIG. 12 illustrates a block diagram of a FET switch 706 used to controlthe functionality of the HVAC system. As described above, the thermostatmay basically act as an intelligent switch for making connectionsbetween pairs of wires from the HVAC system in order to activate variousHVAC functions, such as air conditioning or heating. The FET switches706 may be implemented as simple relays in some embodiments. However, inadvanced thermostats, such as the smart-home thermostat described above,the FET switches may include more advanced switching mechanisms andmonitoring/diagnostic features as described below.

The expanded view 1202 of the FET switch 706 in FIG. 12 shows anintegrated circuit 1204 that includes a pair of high-voltage CMOS FETswitches that connect the primary inputs and outputs 1206. The pair ofinputs/outputs 1206 may be configured to receive a 24 VAC signal fromthe HVAC system. As described above, in order to actuate an HVACfunction of the HVAC system, the thermostat can connect a call relaywire to a corresponding power return wire. For example, to turn on anair conditioner, the thermostat can connect a Y call relay wire to anR_(c) power return wire. The pair of switches can be used to make thisconnection. Some of the embodiments described herein may includesolid-state switching elements in the place of traditional relays as thepair of switches. Solid-state switching elements may offer advantagessuch as the ability to rapidly switch on and off, and to do sorelatively silently compared to traditional relays. Solid-stateswitching elements may be of particular importance in thermostats withpower stealing capabilities. For example, during active power stealingwhen the thermostat is actively calling for an HVAC function byconnecting a power return wire to a call relay wire, power stealingcircuitry may need to momentarily disconnect the power return wire fromthe call relay wire in order to generate a voltage differential acrossthese terminals. The power stealing circuitry can then use the voltagedifferential to charge power storage elements, such as capacitors and/orrechargeable batteries. However, the call relay wire should only bedisconnected from the power return wire momentarily, such that thecurrent in the transformer of the HVAC system does not dissipate enoughto turn off the HVAC function. Therefore, high-speed switching elements,such as solid-state switches, may be beneficial in power stealingthermostats.

In this particular embodiment, two or more field effect transistors(FETs) may be used as switching elements. A switch driver circuit canprovide an output voltage to bias the gate of each of the FETs in orderto control their operation. The switch driver circuit can be controlledby a digital control unit that receives signals from, for example, thesecondary processor 708 to open/close the pair of switches. It will beunderstood that other numbers and/or types of switching circuit elementsmay be used in place of the FETs of FIG. 12 without departing from thescope of the present disclosure.

In order to detect a power anomaly across the pair of input/outputswitches, a limit detection module can monitor the drain-to-sourcevoltages of the FETs. These voltage measurements can be used to detectabnormally high voltage levels across the pair of switches. Thesevoltage measurements can also be used to calculate abnormally highcurrents running through the FETs. For example, the limit detectionmodule can use the measured voltage difference between the drain andsource of the FETs in order to determine when the current runningthrough the FETs has reached an excessive level. The precisevoltage/current levels detected by the limit detection module may varywith each embodiment and potential application. For example, onethermostat embodiment may allow currents ranging between approximately3.3 A to 7.2 A depending on temperature (which in turn may range between−40 C and 125 C), with a typical value of 5.5 A at normal operatingtemperatures. Some embodiments may use a tighter acceptable currentrange, such as 3.5 A to 3.95 A. In one dual-FET embodiment, the two FETscombined may include an on-resistance of between 75 mΩ and 200 mΩ in atemperature range of between −10 C and 60 C, with a typical value ofapproximately 105 mΩ. The limit detection module may allow for momentaryglitches of high current/voltage without tripping. For example, oneembodiment may allow high voltage/current glitches lasting less thanapproximately 25 μs to pass without triggering a response by the limitdetection module.

The integrated circuit 1204 may also include voltage isolation circuitrythat isolates the rest of the thermostat from the relatively highvoltages/currents that may be received through the input/output ports1206. In some embodiments, capacitive and/or inductive isolation may beused. In other embodiments where particularly high voltages may becommon, RF or optical isolation techniques may also be used. The digitalcontrol can communicate with the switch driver through the high voltageisolation circuitry by using, for example, pulsed square wave patternsthat are combined with enable signals.

In FIG. 12, the secondary processor 708 may play an important role in apower stealing cycle. The secondary processor 708 monitors the voltageon the storage capacitor 722 and provides the signals to the integratedcircuits 1204 to open/close their internal FET switches to both activateHVAC cycles and to momentarily open the FET switches to generate avoltage differential required to charge the storage capacitor 722through power stealing. The secondary processor 708 has an internal ADCthat monitors the voltage on the storage capacitor 722. Therefore, inthe embodiment of FIG. 12, the integrated circuit 1204 that actuallyperforms the switching operation to connect pairs of HVAC wires is not“aware” of any timing requirements or external voltages that are used tocontrol the FET switches. Instead, the secondary processor 708 is incharge of monitoring voltage, establishing timing requirements,determining when a power harvesting cycle should begin/end, and soforth.

FIG. 13A illustrates an embodiment of a solid state relay (SSR)switching integrated circuit (IC) 1302 that combines high voltageisolation and gate control of the FET switches with digital control,timing generation, a digital communication bus, voltage references andcomparators, and other onboard monitoring/diagnostic systems. Two wiresfrom the HVAC system 1304 (e.g., a Y wire and an Rc wire) can beconnected to the thermostat 1306 through a pair of HVAC wire connectors1308 configured to receive those particular HVAC wires. The 24 VACsignal between the HVAC wires can be fed into the full-wave bridgerectifier 720 as shown in FIG. 13A. That rectified signal can continueto store charge on the storage capacitor 722 as described above.However, instead of feeding the voltage signal from the storagecapacitor 722 into the secondary processor, that voltage level caninstead be provided to a pin 1336 of a SSR switching IC 1302.

The SSR switching IC 1302 may include a single integrated circuit (IC)package that incorporates all the functionality shown in FIG. 13A into asingle fabrication process. The pin 1336 can be designated as a voltageinput to be measured by the SSR switching IC 1302. The voltage input canbe passed through an optional resistor 1338, and then fed into theinternal circuitry of the SSR switching IC 1302. Resistor 1338 may workwith a diode to ground to protect the SSR switching IC 1302 in caseswhere a higher voltage may be present on V_SENSE. Some embodiments mayalso include fuses outside the SSR switching IC 1302. For example, aresettable PTC fuse between the diode bridge 720 and ground may bepresent. Other fuses may be present between the wire connectors for Rh,Rc, and C, and the rest of the circuits inside the thermostat, such asthe diode bridge 720 and the SSR switching IC 1302. The SSR switching IC1302 may operate the function of a resettable fuse conceptually, sinceit has over-current and over-voltage detection, and can turn itselfon/off. In the context of power stealing, the SSR switching IC 1302 canbe responsible for measuring and monitoring the voltage on the storagecapacitor 722. In some embodiments, a multiplexer 1320 can receive anumber of different analog inputs from different portions of the SSRswitching IC 1302, including the voltage VBR input through pin 1336 fromthe storage capacitor 722. For example, inputs may include a voltage “VSense” measured across the switching FETs 1310, a current “I Sense”measured through the switching FETs 1310, and/or a temperaturemeasurement from a temperature sensor near the switching FETs 1310. Themultiplexer 1320 can select one of these analog inputs as an input to ananalog-to-digital converter (ADC) 1318, which can convert the analogsignal into a digital signal for a timing circuit 1324, and/or a digitalcontrol circuit 1322.

The voltage VBR on the storage capacitor 722 received through pin 1336can also be fed into a pair of analog comparators 1328, 1330. These canbe used to compare the voltage VBR on the storage capacitor 722 to alower threshold and an upper threshold represented by voltage reference1332 and voltage reference 1334, respectively. In some embodiments, thevoltage references 1332, 1334 can be hardcoded into the SSR switching IC1302. In some embodiments, the voltage references 1332, 1334 can bereceived from external circuits through pins (not shown) of the SSRswitching IC 1302. For example, an external voltage divider could becoupled to an input pin of the SSR switching IC 1302 to provide thevoltage references 1332, 1334. In some embodiments, the voltagereferences 1332, 1334 can be set digitally by the digital control 1322and fed into the comparators 1328, 1330. For example, the secondaryprocessor 708 can send commands via an I²C bus controller 1326 to thedigital control 1322 of the SSR switching IC 1302 to digitally set thevoltage references 1332, 1334. In these embodiments, the digital control1322 can provide a pair of programmable analog outputs through adigital-to-analog converter (DAC) to serve as the voltage references1332, 1334. One advantage of this embodiment is that different valuesfor the reference voltages 1332, 1334 can be instantiated via a softwareupdate or other digital communications between secondary processor 708and a remote site, such as a smartphone or workstation of a technicianor customer support agent who may be troubleshooting the smart-homedevice. Alternatively, the updating of reference voltages 1332, 1334 (orany other programmable voltage or setting on the smart-home device) canbe carried out as part of a larger-scale product update across a largepopulation of smart-home devices. By way of example, for the specificcase of a smart thermostat, in the years after thermostat installation,it might be found one day by the thermostat manufacturer that certainHVAC systems branded “XYZA” may have a certain defect or sensitivity forwhich it is best to modify these reference voltages on the associatedthermostat, and a large-scale update for all thermostat customers knownto have HVAC system “XYZA” can be issued to remedy the issue promptly,without requiring large scale technician visits to homes, large-scaleproduct replacements, product recalls, or the like.

In the context of power stealing, the SSR switching IC 1302 can monitorthe voltage on the storage capacitor 722 in real time to determine whenthe switching FETs 1310 need to be turned on/off. When an HVAC functioninvolving the HVAC wires connected to the SSR switching IC 1302 has beeninitiated, the voltage differential between the HVAC wire connectors1308 will be at or near zero because the switching FETs 1310 will beturned on. Because there is no voltage differential, no power can beharvested from the HVAC system 1304 when the FET switches 1310 areclosed. Therefore, as described in detail above, active power stealingwhile the HVAC function is active may include opening the FET switches1310 for brief intervals to generate the required voltage differentialbetween the HVAC wire connectors 1308.

Specifically, the FET switches used in HVAC applications need to switchwhat can be a relatively high inductive load of the HVAC system forbrief instances during power stealing. When the HVAC function is activeand the FET switches 1310 are on, briefly turning the FET switches 1310off can generate an inductive kickback voltage that is generated by theHVAC relay and/or the HVAC transformer. This kickback voltage can be feddirectly through the full-wave bridge rectifier 720 and into the storagecapacitor 722. In some embodiments, the gate control unit 1314 candetect zero crossings of the input AC waveform from the HVAC system andturn on/off the switching FETs 1310 at zero crossings, thereby reducingstress on the FET switches 1310. Additionally, the gate control 1314 canensure that there are no shoot-through currents so that the switchingFETs 1310 turn off correctly. In other embodiments, the zero-crossingdetection can alternatively turn on the switching FETs 1310 at a peakvoltage rather than a zero crossing voltage. Similarly, the switchingFETs 1310 can be turned off at a zero-crossing for the current waveform,which can reduce the kickback.

Although not shown explicitly in FIG. 13A, some embodiments may includea lead from the pair of gate drivers 1312 that extends to a pad and I/Opin on the SSR switching IC 1302. This pin can be bonded to a bond-outpad when not in use. However, in other embodiments, this pin could betied to the gate of additional external switching circuits. For example,high-voltage FETs could be used for different applications with higherload voltages. These high-voltage FETs could be mounted on the circuitboard with the SSR switching IC 1302 and connected to these pins.Therefore, the SSR switching IC 1302 could be used to control externalswitches for a wide variety of applications using the same serial buscommands from the secondary processor 708.

In the embodiments described herein, the SSR switching IC 1302 canprovide new control methods for power stealing using the inductivekickback voltage generated by the inductive loads of the HVAC system.The timing circuit 1324 can receive a digital representation of thevoltage on the storage capacitor 722 through the ADC 1318. The timingcircuit 1324 can also receive signals originating from the comparators1328, 1330 indicating whether the voltage on the storage capacitor 722has crossed the upper and/or lower thresholds. The timing circuit 1324can then generate timing signals for the digital control 1322. Thesetiming signals can be passed into the gate control circuit 1314 for theswitching FETs 1310.

The digital control 1322 can communicate with the gate control circuit1314 through a high voltage isolation circuit 1316. For example,capacitive or inductive coupling can be used to isolate the circuitryinside the high voltage isolation boundary 1350 from the rest of the SSRswitching IC 1302 and the thermostat 1306. For example, clocked squarewave pulses can be used in conjunction with digital enable signals fromthe digital control 1322 in order to send signals through the highvoltage isolation circuit 1316 into the gate control 1314. The gatecontrol 1314 can be used to drive a pair of gate drivers 1312 that turnon/off the switching FETs 1310. A charge pump 1391 may be included withan external capacitor to move energy from the low-voltage circuitry ofthe SSR switching IC 1302.

In some embodiments, diagnostic sensors can be located near theswitching FETs 1310 to provide real-time and historical diagnosticinformation that can be recorded by the SSR switching IC 1302 and usedfor real-time control operations and/or later diagnostic operations. Forexample, a temperature sensor 1356, a current sensor 1354, and/or avoltage sensor 1352 can be located near the switching FETs 1310. Thecurrent sensor 1354 can measure a current passing through the switchingFETs 1310. The voltage sensor 1352 can measure a voltage across theswitching FETs 1310. The temperature sensor 1356 can monitor thetemperature on the IC near the switching FETs 1310. Each of the sensorreadings may be recorded by the gate control 1314 and passed through thehigh voltage isolation circuit 1316 to the digital control 1322 of theSSR switching IC 1302. In other embodiments, analog outputs of thesensors can be passed through the high voltage isolation boundary 1350and provided as inputs to the multiplexer 1320. The digital control 1322can include one or more memory elements that store historical datarecorded from the voltage sensor 1352, the current sensor 1354, and/orthe temperature sensor 1356. In some embodiments, the digital control1322 can pass these values to the secondary processor 708 through theI²C controller 1326.

The secondary processor 708 can communicate with the SSR switching IC1302 through a bus protocol. In this particular embodiment, the SSRswitching IC 1302 uses an I²C bus as an example. Other embodiments mayuse other bus protocols that may be provided with other processors. TheI²C protocol includes a clock (SCL), a data line (SDA), and a two-bitaddress line that can be used to set the address of the SSR switching IC1302. Therefore, the secondary processor 708 can communicate with aplurality of different FET switching circuits 1302 by giving each SSRswitching IC 1302 a different address. The address pins (ADD0, ADD1) canbe connected to external power/ground signals through pull-up/pull-downresistors to set the bus address for each SSR switching IC at thecircuit-board level. For example, the thermostat 1306 may include a SSRswitching IC 1302 for a heating function, a cooling function, and a fanfunction. Each of these different functions may be associated with adifferent call relay wire from the HVAC system 1304, and may further beassociated with their own dedicated SSR switching IC 1302. In someembodiments, only one channel of one SSR switching IC 1302 is engaged inpower stealing at any given point. The processor 708 determines whichHVAC call relay wire is connected to the diode bridge 720 and modulatesthat particular channel on the associated SSR switching IC 1302. If aC-wire is present, then no SSR switching ICs 1302 may need to performpower stealing in some embodiments. The processor 708 may determine thatnone of the HVAC call channels are connected to the diode bridge 720,and thus none would be modulated. Generally, an SSR switching IC channelis used for every call wire.

In a similar design according to another embodiment, nearly all of thecircuit elements outside of the high-voltage isolation barrier 1350would be provided either by discrete circuitry on the thermostat circuitboard or by internal functions of the thermostat microprocessor 708.However, by incorporating the digital control 1322, the timinggeneration module 1324, the ADC 1318, the multiplexer 1320, the voltagereferences 1332, 1334, etc., into the SSR switching IC 1302, the designcan be greatly simplified and ultimately cost less to implement. Insteadof sending clock pulses through the isolation barrier 1350, thethermostat processor 708 can simply send serial bus commands to the SSRswitching IC 1302. Furthermore, the high-voltage isolation circuit 1316can become a design decision internal to the SSR switching IC 1302,which can be tailored for the voltage requirements of each specificapplication.

FIG. 13B illustrates an embodiment of an SSR switching IC 1302 thatcombines high voltage isolation and gate control of the FET switcheswith digital control, timing generation, a digital communication bus,voltage references and comparators, and other onboardmonitoring/diagnostic systems. This embodiment is similar to theembodiment of FIG. 13A, the difference being the way in which the SSRswitching IC 1302 is addressed over the serial communication bus. Recallthat in a typical thermostat application, a plurality of SSR switchingICs 1302 will be used to control the switching functions of various HVACoperations. In FIG. 13A, the individual SSR switching IC's 1302 wereaddressed using address pins through which each individual SSR switchingIC 1302 can be assigned an individual address using pull-ups/pulldowns.In the embodiment of FIG. 13B, one or more resistors 1360 may be addedto pins on the SSR switching IC 1302 in order to set the address. Someembodiments may use external pull-down resistors of various values foreach SSR switching IC 1302, internal current sources that pull theresistors up, and comparators. Some embodiments may also use a singlecurrent source and the ADC 1318. The resistor value may be detected, andan I²C address may be assigned based on a range of, for example, 8values. This allows up to 8 devices on the same I²C bus at differentaddresses. Instead of address lines coming from the secondary processor708, the enable line (EN) can be used to select and enable theparticular SSR switching IC 1302. While the EN line may be present inthe embodiments of both FIG. 13A and FIG. 13B, the EN line in FIG. 13Bcan be used to control the reception of bus communications withoutrelying on the address pins. The EN signal may also be used to provide asafe reset of the SSR switching IC to keep the protection circuits inplace and turn off gracefully.

FIG. 14 illustrates a thermostat circuit architecture using the SSRswitching IC 1302, according to some embodiments. The circuit in FIG. 14can be compared to the circuit in FIG. 12. In FIG. 14, each of the FETswitches 706 have been replaced by the SSR switching IC 1302 from FIG.13A. The individual FAULT and CTL lines have been replaced with an I²Cbus that runs from an I²C port on the secondary processor 708 andconnects to each of the FET switching circuits 1302 in the thermostat.Additionally, instead of sending the voltage on the storage capacitor722 into the ADC of the secondary processor 708 as in the embodiment ofFIG. 12, the voltage is sent directly to the SSR switching ICs 1302.Note that the storage capacitor 722 may still be coupled to thesecondary processor 708 for other functions, but this connection betweenthe storage capacitor 722 and the secondary processor 708 is no longernecessary for active power stealing. In operation, the secondaryprocessor 708 can send a command on the I²C bus that is addressed to aparticular SSR switching IC 1302 in order to activate an HVAC functionusing, for example, the W or Y wires. After activating the HVACfunction, the secondary processor 708 need not actively monitor thevoltages related to the power stealing for this embodiment. Instead, theFET switching circuits 1302 can independently monitor the voltage on thestorage capacitor 722 and time the opening/closing of their internal FETswitches based on the stored/set voltage references. In some alternativeembodiments, however, the secondary processor 708 can still control theactive power stealing cycles of the thermostat using a general-purposeI/O on the SSR switching IC 1302 as the switch on/off signal.

FIG. 15 illustrates a timing diagram using minimum and maximumthresholds to control power stealing intervals, according to someembodiments. In this embodiment, the timing circuit 1324 of FIG. 13A canuse the voltage references 1332, 1334 and the comparator outputs 1328,1330 to generate timing signals for the gate control 1314 for the FETswitches 1310. Specifically, when the voltage on the storage capacitor722 dips below the level of the lower voltage reference 1332, the outputof the comparator 1330 will go high. In response, the timing generationcircuit 1324 can cause the digital control 1322 to issue a command tothe gate control 1314 to open the FET switches 1310. Opening the FETswitches 1310 will generate a voltage differential across the two HVACwire connectors 1308. This voltage differential can be used to beginrecharging the storage capacitor 722 through the full-wave bridgerectifier 720.

As described above, the FET switches 1310 can only stay open for a shortamount of time during an active HVAC cycle. Otherwise, opening theswitches will cause the trigger circuit of the HVAC system 1304 to turnoff the HVAC function. For example, opening the connection between the Yand R_(c) wires for an extended length of time will turn off theair-conditioning function of the HVAC system. The goal of the SSRswitching IC 1302 is to open the FET switches 1310 for a time intervalthat is long enough to charge the storage capacitor 722, but not longenough to turn off the triggering circuit of the HVAC system 1304.

Turning back to FIG. 15, voltage 1514 represents the voltage between theHVAC wire connectors 1308. Voltage 1512 represents the voltage VBR onthe output of the full-wave bridge rectifier 720 that is stored on thestorage capacitor 722. Signal 1516 represents the state of the FETswitches 1310. Prior to time 1510, the associated function (e.g.,air-conditioning) of the HVAC system 1304 is not activated, and thussignal 1516 indicates that the FET switches 1310 are in the OFF state.Voltage 1514 oscillates, representing the full 24 VAC signal from theHVAC system. This causes the voltage 1512 on the storage capacitor 722to remain comfortably above the upper threshold 1520.

At time 1510, the HVAC function can be activated, and signal 1516indicates that the FET switches 1310 transition to the ON state. In thisembodiment, the system turns on at a zero crossing at time 1510 for theinput AC voltage signal. In other embodiments, the system can insteadturn on at a time corresponding to a voltage peak of the input ACvoltage signal instead of at a zero-crossing. When the FET switches 1310are closed, the voltage 1514 across the HVAC wire connectors 1308 isgreatly reduced. Consequently, the rectified voltage 1524 drops belowthe voltage 1512 on the storage capacitor 722. The rectified voltage1524 represents a theoretical output of the rectifier if the storagecapacitor 722 were not present. Since the storage capacitor 722 iscoupled to the output of the rectifier, this voltage would be equal tothe voltage on the storage capacitor 722 because the bridge diode wouldnot conduct. Because the charge on the storage capacitor 722 is used toprovide power to the PMIC 802 for operating the thermostat and chargingthe rechargeable battery 730, the charge 1512 on the storage capacitor722 begins to drop, as it is no longer being constantly recharged by ahigher rectified voltage from the full-wave bridge rectifier 720.

At time 1502, the voltage 1512 drops below the lower threshold 1522.This lower threshold 1522 can be determined by the lower voltagereference 1332. In response, the timing generation circuit 1324 cancause the digital control 1322 to issue a command to the gate control1314 of the SSR switching IC 1302 to temporarily transition the FETswitches 1310 to the OFF state. After time 1502, voltage 1514 on theHVAC wire connectors 1308 begins to rise sharply as a result of theinductive kickback from the HVAC system. The resulting charge is dumpedonto the storage capacitor 722.

To determine when the FET switches 1310 should be closed, the timinggeneration circuit 1324 can use a number of different methods. In theembodiments of FIG. 15, the timing generation circuit 1324 can monitorthe signal from the comparator 1328 that uses the high voltage reference1334, which corresponds to the upper threshold 1520. When the voltage1512 reaches the upper threshold 1520, the timing generation circuit1324 can cause the digital control 1322 to issue a command to the gatecontrol 1314 of the SSR switching IC 1302 to transition the FET switches1310 back to the ON state at time 1504.

The time interval between time 1502 and time 1504 occurs during apositive cycle of the voltage 1514 from the HVAC system. A similar timeinterval between time 1506 and time 1508 occurs when the voltage 1514from the HVAC system is in a negative cycle. The shape of the voltagesignal of the inductive kickback is substantially the same as it isduring the positive cycle, but the magnitude will be negative. This doesnot affect the charging of the storage capacitor 722 because thenegative inductive kickback is made positive through the full-wavebridge rectifier 720.

FIG. 16 illustrates a flowchart of a method for controlling powerstealing using a SSR switching IC with upper/lower voltage comparators,according to some embodiments. Note that this method refers to the useof solid-state relays (SSRs) instead of specifically to FET switches.Although the embodiments described above use FET switches as aparticular implementation, other types of SSRs may also be used, such asa single MOSFET, parallel MOSFETs, bidirectional MOSFETs, SCR or TRIACrelays, BJTs, IGBTs, and so forth. Therefore, in every instance whereFET switches are used in this disclosure, other SSRs may also be used inany combination and without limitation.

This method may be carried out by the SSR switching IC 1302 of FIG. 13Aas installed in the thermostat 1306. The method may include receiving acommand to close the SSRs and activate an environmental function (1602).The environmental function may be associated with a particular pair ofenvironmental control wires that are connected to the FET switchingcircuit, such as a Y wire and an Rc wire to activate an air-conditioningfunction. The method may also include causing the SSRs to close (1604)in response to receiving the command to activate the environmentalfunction. After causing the SSRs to close, the FET switching circuit canmonitor the voltage on an energy storage element (1606). The energystorage element may include a storage capacitor, rechargeable battery, asuper capacitor, and/or the like.

While monitoring the voltage on the energy-storage element, the FETswitching circuit can compare the monitored voltage to a lower voltagethreshold (1608). The lower voltage threshold may be provided through apin of the SSR switching IC, programmed through a communication bus tothe SSR switching IC, and/or set using internal voltage references ofthe SSR switching IC. As long as the monitored voltage stays above thelower threshold, the SSRs can remain closed and the SSR switching IC cancontinue to monitor the voltage on the energy storage element. As soonas the monitored voltage falls below the lower threshold, the SSRswitching IC can cause the SSRs to open temporarily (1610). The SSRs canremain open until the monitored voltage surpasses an upper threshold(1612). When the upper threshold is crossed, the SSR switching IC canclose the SSRs (1604), and then repeat the cycle of monitoring thevoltage on the energy-storage element. As with the lower threshold, theupper threshold may be provided through a pin on the SSR switching IC,programmed through a communication bus, and/or set using internalvoltage references.

FIG. 17 illustrates a timing diagram using a minimum threshold and atiming requirement to control power stealing intervals, according tosome embodiments. FIG. 17 is similar to FIG. 15, the difference beingthat instead of using the upper threshold 1520, a time limit is used toturn off the FET switches 1310. As described above, when the voltage1512 drops below the lower threshold 1522, the FET switches 1310 cantransition to the OFF state. However, instead of remaining in the OFFstate until the voltage 1512 reaches the upper threshold 1520, the FETswitches 1310 can be transitioned to the ON state after a time intervalhas expired. This time interval is depicted as beginning at time 1502and expiring at time 1704. For the negative cycle, the time intervalbegins at time 1506 and expires at time 1708. The time interval can beset using commands received from the secondary processor 708 and can bedynamically programmable.

In this example, the time interval expires before the voltage 1512reaches the upper threshold 1520. In other embodiments, the timeinterval may also be longer, such that the voltage 1512 is allowed tosurpass the upper threshold 1520 before the time interval expires, andthus the voltage 1512 on the storage capacitor 722 may exceed the upperthreshold 1520. In some embodiments, both the time interval and theupper threshold 1520 may be used in conjunction to govern when the FETswitches 1310 are transitioned back to the ON state. The timing intervalmay be set such that it is shorter than the length of time that wouldcause the HVAC system to turn off the associated HVAC function. In theseembodiments, the FET switches can remain in the OFF state until eitherthe voltage 1512 has surpassed the upper threshold 720, or the timeinterval has expired. These embodiments ensure that the FET switches donot remain in the OFF state long enough to disrupt the HVACfunctionality, and also ensure that the power stealing interval lastonly as long as needed to charge the storage capacitor 722. The mode inwhich the SSR switching IC 1302 runs can also be dynamically set by thesecondary processor 708 through the bus. For example, the SSR switchingIC 1302 can be instructed to operate in a comparator-only mode, atimer-only mode, a comparator-and-timer mode, and so forth.

FIG. 18 illustrates a flowchart 1800 of a method for controlling powerstealing using a SSR switching IC with a lower voltage comparator and atime interval, according to some embodiments. As described above, themethod may include receiving a command to close the SSRs and activate anenvironmental function (1802) of an environmental system, such as anHVAC system, by which the SSRs can be closed in response (1804). In someembodiments, the SSR switching IC may include one or more switchingelements, such as a pair of FETs, that operate in at least two operatingstates. In a first operating state, the one or more switching elementsmay create a connection between a power wire connector of the smart-homedevice and a return wire connector of the smart-home device. In a secondoperating state, the one or more switching elements may interrupt theconnection between the power wire connector and the return wireconnector.

As described in detail above, the SSR switching IC may include a digitalcontrol circuit that controls the one or more switching elements. Afterreceiving a command to activate the environmental function, for example,via the serial bus interface, the SSR switching IC can cause the one ormore switching elements to operate in the first operating statedescribed above to activate the environment function. For example, thethermostat processor can send a command to the SSR switching IC toactivate a heating function by closing the FETs to create a connectionbetween the heating call relay wire and the corresponding power returnwire.

The SSR switching IC can monitor the voltage on the energy-storageelement (1806) until an electrical property of the energy-storageelement has dropped below a first threshold while the one or moreswitching elements operate in the first operating state (1808). Forexample, the SSR switching IC can determine when the voltage drops belowa lower threshold. Some embodiments of the SSR switching IC may includeone or more references, such as voltage references, that are coupled toone or more comparators that are used to compare an electricalcharacteristic of the energy-storage element to the references.

At this point, the SSRs can be opened to allow the power harvestinginterval to begin (1810) by causing the one or more switching elementsto operate in the second state described above. The SSR switching IC canmonitor a timer (1812), and when the timer expires (1814) after a firsttime, the one or more switching elements can be closed (1804), or causedto operate in the first state again. The cycle can then restart asneeded. In some embodiments, the one or more switching elements can alsobe closed (1804) in response to the voltage passing an upper thresholdas described above for FIG. 16 as well. It will be understood that theterm “one or more switching elements” may be equivalent to any of theswitching technologies, such as SSRs, described herein or commerciallyavailable.

FIG. 19 illustrates an SSR switching IC 1302 with two different,parallel sets of SSR circuits. This design integrates multiple SSRcircuits, each with their own independent high-voltage isolationcircuitry 1316, gate drivers 1312, and telemetry sensors (e.g., voltagesensing 1352, current sensing 1354, temperature sensing 1356, etc.)together with a single control system on the SSR switching IC 1302. Thedigital control 1322 can independently control each of the multiple SSRcircuits based on commands received from a master controller through theserial bus and/or using sensor and other inputs indicating timing andperformance characteristics of waveforms as described above.

This configuration may be advantageous when the SSR switching IC 1302 isused to control HVAC systems where the fan and cooling function arecontrolled by independent call relay and return wires. For example, thebottom SSR circuit in FIG. 19 may be connected to a cooling functioncall relay wire with a corresponding power return wire, while the topSSR circuit in FIG. 19 may be connected to a fan call relay wire with acorresponding power return wire. The SSR circuit connected to thecooling function can operate according to the power-harvesting timingprotocol described in detail above, momentarily switching off in orderto create a voltage difference across the input terminal such that powercan be harvested from the HVAC system. Meanwhile, the SSR circuitconnected to the fan can continue to operate as normal according to thesetpoint schedule of the thermostat. The combination of these twofunctions can be controlled by a single set of commands via the I²C busfrom the thermostat microcontroller. For example, a processor on thethermostat may send a command to the SSR switching IC 1302 thatinstructs the SSR switching IC 1302 to activate the cooling function.The digital control 1322 may then send separate commands to each of themultiple SSR circuits through their respective high-voltage isolationcircuits 1316 to independently control each, briefly and periodicallyopening at least one of the SSR connections if power stealing isrequired.

This configuration in FIG. 19 may be advantageous in that it can reducedthe number of SSR switching ICs 1302 that may be required for aparticular application. For example, as shown in FIG. 7, as many asseven separate SSR switching ICs 1302 may be needed to replace the sevenFET switches 706 if each IC includes only a single SSR circuit. Incontrast, the number of SSR switching ICs 1302 may be cut in half ormore if multiple SSR circuits are placed on each chip. It should benoted that the configuration illustrated in FIG. 19 is shown merely asan example and is not meant to be limiting. Specifically, the number ofindependent SSR circuits on each chip can number more than two. Eachadditional SSR circuit can be connected to the digital control 1322 viaa serial bus such that the digital control 1322 can individually addresseach of the multiple SSR circuits on the chip. The individualcommunication may use enable lines, address lines, or dedicatedcommunication lines to each SSR circuit.

Additionally, each of the multiple SSR circuits 1350 may include theirown telemetry sensors and connections to the multiplexor 1320 and/or theADC 1318. Thus, the performance characteristics of each of the SSRcircuits can be simultaneously and independently captured and stored bythe digital control 1322. In some embodiments, the multiplexor 1320 andADC 1318 can be shared amongst the multiple SSR circuits, while in otherembodiments each of the multiple SSR circuits may have its own dedicatedmultiplexor 1320 and ADC 1318.

FIG. 20 illustrates a thermostat configuration that uses two SSRswitching ICs 1302 to interface with HVAC systems having multipletransformers, according to some embodiments. Some HVAC systems mayinclude two different triggering circuits, each having their owntransformer. In the example described above, the HVAC system may includean HVAC function (e.g., cooling) that uses a first transformer 2004 anda second transformer 2002. As described above, the functions of each ofthese transformers 2004, 2002 can be controlled individually andindependently by a single SSR switching IC 1302-2 via commands from theprocessors 708 of the thermostat through the serial bus. This offloadsthe control and complexity of the controlling the timing of the SSRoperation from the processor 708 and abstracts the specifics of theparticular switching technologies used to control the HVAC transformersfrom the processor. This allows for greater flexibility when selecting,upgrading, and programming processors for the thermostat. For example,offloading these functions to the SSR switching ICs 1302 allows for morepower-efficient and/or low-cost processors to be used in the thermostat.

In some embodiments, the transformers 2004 and 2002 may be in phase witheach other. However, in order to provide a robust design, the SSRswitching IC 1302-2 having more than one SSR circuit may be designed tohandle peak current and voltage signals for cases where the twotransformers 2004, 2002 are 180° out-of-phase with respect to eachother. For example, the first transformer 2014 may control the “W” wireof the HVAC system, while the second transformer 2002 may control the“Y” wire of the HVAC system. Each of these signals may normally beapproximately a 24 VAC (RMS) waveform, which produces approximately 32Vmaximum RMS. This standard signal may also occasionally produce spikeshaving a peak voltage of 45V-55V. Therefore, the SSR switching IC 1302-2may be designed to handle at least twice the 55V spikes, resulting in anSSR circuit that is robust against spikes exceeding 110V (e.g., 130V,150V, 160V, 175V, 200V, etc.). Even though the FETs in the SSR circuitmay not be exposed to this voltage-doubling effect, the shared isolationbarrier for each of the SSR circuits may be. Therefore, the high-voltageisolation barrier and circuitry may be designed to handle the peakvoltage for each individual transformer multiplied by the number of SSRcircuits inside the shared isolation region.

As described above, the type of isolation barrier used in each of theSSR circuits can depend on the expected voltage/current signal ranges towhich the barrier will be subjected during operation in each particularapplication. In the thermostat application described above, the expectedvoltages and currents in the dual SSR circuit configuration where thetwo transformers can be 180° out-of-phase with each other are low enoughthat normal high-voltage circuit components can be used to provideisolation, such as high-voltage FETs, on-die capacitive isolation, andlevel shifters. This is advantageous because it is a simple solutionthat can keep the cost per SSR switching IC 1302 relatively low. Inother applications where a larger number of SSR circuits may share anisolation barrier or where higher voltage/current spikes may beanticipated, more robust voltage-isolation circuitry may be used, suchas inductive isolation, RF isolation, optical isolation, and so forth.

FIG. 20 illustrates an SSR switching IC 1302-1 that is connected inparallel with the SSR switching IC 1302-2. Each of these SSR switchingICs 1302 may share the same serial bus from the microprocessor 708 ofthe thermostat. However, the SSR switching IC 1302-1 is only connectedto a single transformer 2006 in the HVAC system. The single transformer2006 has two separate relays 2008, 2010 that are each connected to oneof the two input/output pins of the SSR switching IC 1302-1. In anotherconfiguration where the single transformer 2006 has only a single relay,each wire from the HVAC system can be connected to each of the availableinput and output pins of the SSR switching IC 1302-1. The digitalcontrol of the SSR switching IC 1302-1 can be instructed to send thesame control signals to each of the SSR circuits such that they operatein unison. This configuration also splits the current between each ofthe multiple SSR circuits in the SSR switching IC 1302-1.

FIG. 21 illustrates a block diagram of how telemetry data can be savedand recorded from each of the SSR circuits, according to someembodiments. As described above, each of the SSR circuits may includevarious telemetry sensors embedded in the IC near the actual switches.These sensors may include circuits for sensing voltage measurementsacross the switches, current measurements through the switches,temperature measurements in the silicon surrounding the switches, and soforth. These sensors can receive analog measurements and provide analogsignals to the multiplexor 1320. The multiplexor can cycle through eachof its inputs, sequentially selecting each of the telemetry inputs basedon a conversion cycle time of the ADC. The ADC can be programmed tosuccessively and continuously convert the analog measurements from thesensors into a digital form that the digital control of the SSRswitching IC 1302 can receive. In some embodiments, each sensor may haveits own dedicated ADC such that readings from each sensor can truly becaptured in parallel. Some embodiments may also include other sensorsother than those shown in FIG. 21.

The ADC 1318 can provide a time series of samples 2102, 2106, 2108 tothe digital control 1322 for each of the monitored sensors. In someembodiments, the digital control 1322 can receive the time series ofsamples 2102, 2106, 2108 and store the samples in a memory 2112. Thememory 2112 may operate as a FIFO queue, saving samples until an amountof memory allocated for each particular sensor is full, then writingover the oldest samples to maintain a sliding window 2122 of sampleswith a window length that is proportional to the size of the allocatedmemory. The contents of the memory 2112 can be used to create a historylog of operations for each sensor. Even during normal operations duringwhich no faults are detected, this history log can be used tocharacterize operation of the SSRs, to test new software techniques foroperating the digital control 1322, to diagnose and detect intermittentproblems, to anonymously aggregate data characterizing the install baseof an HVAC system, and/or to detect changes in system operation overtime.

In some embodiments, the digital control 1322 may include a thresholddetection circuit that can be used to detect electrical anomalies inreal time. The threshold detection circuit may include digitalthresholds 2114 to which the digital samples can be compared as they arereceived. For example, a digital threshold 2104 may be used for thevoltage/current to detect over-voltage/current spikes that could damagethe circuitry of the SSR switching IC 1302. Other digital thresholds maybe used to detect over-temperature situations. Some embodiments mayrequire a certain number of consecutive samples above the thresholdbefore classifying the event as an over-current/voltage spike in orderto act as a low-pass filter on the samples and thereby filter out brieftransient signals that do not risk causing damage. When the digitalcontrol 1322 detects an over-current/voltage condition of a sufficientduration, the digital control 1322 can open the SSRs to prevent damagefrom being inflicted on the SSR switching IC 1302. Generally, thesilicon region of the SSR switching IC 1302 inside the high-voltageisolation barrier can be designed to handle voltage/current levels andheat buildup that may be reasonably expected in to occur in an HVACsystem for a short duration that is longer than the time it takes todetect these anomalies and turn of the SSRs.

The threshold detection circuit 2110 may also include thresholddetection that is more advanced than simple digital thresholds. Forexample, the threshold detection circuit may include a fast-Fouriertransform (FFT) module 2116 that can be used to perform a frequencyanalysis of the time series of samples 2102, 2106, 2108 to detect and/orrecord frequencies that are outside of a normal operating range. Thethreshold module may also use the samples 2102, 2106, 2108 to detectzero-crossings 2118. In some embodiments, the zero-crossings can be usedto time the turning on/off of the SSRs when activating/deactivating anHVAC function and/or temporarily turning of the SSRs during an HVACfunction to enable power stealing. By switching the SSRs off to coincidewith zero-crossings of the 24 VAC HVAC signal, the stress of absorbingexcess current that is generated by interrupting the inductivetransformer of the HVAC system can be effectively minimized. In someembodiments, the gate control of each of the SSR circuits can instead beconfigured to turn the SSRs off at zero-crossings rather than turningoff immediately. Alternatively, if the SSR switching IC is installed ina DC system, the SSRs can be turned off immediately upon detecting afault.

As described above, the memory will capture a real-time waveformrepresented by digital samples of the different sensor measurements. Thememory 2112 can also store statistical information, such as a high/lowfor each sensor, average values, average frequencies, and so forth. Thememory 2112 may also include a fault log 2120 that records the time andconditions surrounding a fault event. The fault log 2120 can store thefault conditions (thresholds, max/min measured values, timing, etc.)along with the actual raw waveform data surrounding the fault. In someembodiments, in order to conserve memory, the historical window ofwaveform data may be relatively small (e.g., 1 hour, 6 hours, 12 hours,24 hours, 1 week, 1 month). Although continuously monitored andrecorded, the waveform samples 2102, 2106, 2108 can be discarded unlessa fault event is detected in the time period surrounding those samples.For example, the waveform data for each hour can be discarded unless afault is detected at some point in that hour, in which case the waveformin the hour window surrounding the fault can be saved to the memory2112. In other embodiments, all waveform data may be saved until thememory 2112 is full and the oldest data are overwritten. In someembodiments, relatively small memory modules may be used by the SSRswitching ICs. For example, one memory may only cover about 30 ms ofsamples. To aggregate more samples than the memory can accommodate, thesecondary processor can periodically (e.g., every 20 ms) read out theSSR switching IC memory and store the data in the secondary processor'smemory, which will generally be much larger. In some cases, thesecondary processor may be configured to only read out data from the SSRswitching IC memory when faults or anomalies are detected. In someembodiments, the secondary processor may also regularly read out datafrom the SSR switching IC memory for long-term analysis, even in theabsence of a detected fault.

FIG. 22 illustrates a flowchart 2200 of a method for using telemetrydata from an SSR switching IC to monitor performance, according to someembodiments. The method may include operating the SSRs to control anenvironmental function (2202). The SSRs may be operated using the SSRswitching IC described in detail above. The SSR switching IC may includevoltage/current/temperature sensors close to the SSRs. The method mayalso include sampling the sensor measurements continuously over time tomonitor the operating characteristics of the SSRs while chip is beingused in an actual installed application. In some embodiments, the methodmay additionally include comparing the samples to various thresholds inreal-time as described above (2206), and storing a history of thewaveform samples in a memory device of the SSR switching IC (2208).

The method may further include copying the data from the SSR switchingIC memory to the local MCU memory for local aggregation, comparison tothresholds, and/or other data analysis (2209). Specifically, the datafrom the SSR switching IC memory can be transferred first to thesecondary processor's memory, then to larger memory in the primaryprocessor. As will be described in detail below, the telemetry datareceived from the SSR sampling circuits can be used in comparison tothresholds to detect voltage/current/temperature anomalies. This datacan also be aggregated to detect data trends that happen over time. Forexample, temperature data can be aggregated to monitor the self-heatingof the device for use in calculating an accurate and compensated ambienttemperature from the thermostat temperature sensor measurements thatmight be affected by internal heating. In another example, aggregatingvoltage/current data can be used to characterize a variety differenttypes of HVAC systems with which the thermostat may be installed. Forexample, the data may be used to detect when an HVAC system is beginningto fail by detecting changing operating characteristics over time. Thisprocessing may take place locally at the SSR switching IC, on thethermostat processor, and/or remotely at a thermostat server.

In some embodiments, the method may additionally include sending thesample history to a server for aggregate analysis (2210). In the exampleof a thermostat, the thermostat may be configured to communicate overthe Internet with a remote thermostat management server that monitorsthe operation of a collection of thermostats. The thermostat server maybe operated by an entity that designs and/or manufactures thethermostats (e.g., Nest Labs®). In some embodiments, the thermostat maycommunicate regularly (e.g., nightly, every 30 min, every 60 min, eachtime the primary processor or user interface wakes up, etc.) with thethermostat server to receive software updates and new operatingparameters, and to provide the thermostat server with diagnostic datathat can be used to study and refine the software running on thethermostat. The sample history from the SSR switching IC can be sentfrom the thermostat to the thermostat server as part of the nightly dataupload.

From the perspective of the remote server, data can be collected from alarge number of SSR switching ICs that are part of many differentdevices that are distributed over a wide geographic area. These devicesmay be installed in many different regions around a country and may besubjected to many different types of operating environments. Therefore,the data collected from these different SSR switching ICs can providediagnostic information that can be used to thoroughly test and evaluatecurrent and future versions of the software that operates on the SSRswitching ICs and inform future hardware designs and factory testprocedures. Specifically, the digital control of the SSR switching ICsmay store software instructions and different parameter values thatcontrol how the SSR switching IC handles commands from an externalmicroprocessor (e.g., the thermostat processor) to operate the internalSSRs. This software in the SSR switching IC can be installed and updatedby downloading a software package from the thermostat server to thethermostat. The thermostat processor can then install/replace thesoftware in the SSR switching IC by programming the digital controland/or the software in the gate drivers via the serial bus of the SSRswitching IC. This installation/updating of the SSR switching ICsoftware can be done while the SSR switching IC is installed andoperating in the thermostat in a user's home without interrupting thenormal operation of the thermostat.

The data aggregated from the SSR switching ICs from multiple thermostatscan used by the thermostat server for many different purposes. In someembodiments, the data collected from the ICs can be used to test newversions of the software that operates on the SSR switching ICs. Thewaveform samples collected from the thermostats can be used as inputdata for new circuits and/or software versions such that can be testedwith large-scale, real-world data. Normally, the new software and/orcircuits would be tested using standalone thermostats in a controlledenvironment. Using the aggregated waveform data from a population ofthermostats can provide a real-world framework for simulating circuitand the software responses to actual voltage/current anomalies thatoccur in the field. New software can be tested against the collecteddata in a limited run before distribution to the wider thermostatpopulation. This can reduce development time for new software versionsand can increase the reliability of software once released. New softwarecan be downloaded to the thermostat while it is operating in a user'shome. The software may update instructions or parameter values that arestored and executed on the SSR switching IC itself. The softwaredownload may also change the way in which the primary/secondaryprocessor interacts with the SSR switching IC.

In some embodiments, the data aggregated from the SSR switching ICs canbe analyzed to identify previously unknown electrical anomalies. Thethermostats in the field will generally have threshold and waveformlimits set to detect known voltage/current anomalies (e.g.,over-current/voltage). What can often be missed are “near-anomalies”where the predetermined thresholds are not triggered, but which maystill cause excessive heat buildup in the silicon IC. For example, alarge pulse of current that lasts for more than a couple of AC cyclesmay not cross the current threshold, yet may still cause excessive heatbuildup. Even in cases where the thresholds are tripped, having thewaveform data can provide a precise and clear picture of whatvoltage/current waveforms were experienced by the SSR switching IC.These waveforms can be used to generate new circuit solutions in thefuture that address the types of electrical anomalies that thethermostats are exposed to in typical installations.

In some embodiments, the aggregated data can be analyzed by thethermostat server to identify subsets of the thermostat population thatare experiencing isolated problems. Aggregated data can also be used toanalyze subsets of the thermostat population that can be groupedaccording to geographic or environmental characteristics, such ascustomers on the same power substation, customers in the same area ofoverhead wires, customers connected to the same utility companies,customers located in areas experiencing strong storm patterns, customersin the same neighborhood, ZIP code, city and so forth. For example, theuploaded data may reveal that thermostats installed in homes with acertain brand of HVAC system experience different types of electricalanomalies (e.g., current surges) then the anomalies experienced by therest of the population. New software versions for the SSR switching ICcan be developed to handle these specific anomalies that only apply tocertain thermostats. Then, the new software versions can be downloadedto the specific thermostats that are likely to be exposed to similaranomalies. For example, a specific version of the SSR switching ICsoftware can be downloaded to thermostats that are paired with bothprimary and secondary heating functions, thermostats paired with acertain brand of HVAC system, thermostats installed in homes with wiringthat is older than a predetermined date, thermostats installed in homeswith a thermal retention characteristic below a certain level, and soforth.

FIG. 23 illustrates a flowchart 2300 of a method for triggering waveformsample storage using predetermined thresholds, according to someembodiments. As described briefly above, some actions performed by thetelemetry system of the SSR switching IC can be triggered based onevents, such as thresholds being exceeded or waveform patterns beingdetected. The method may include operating the SSR switching ICs tocontrol an environmental function (2302), sampling voltage, current,temperature, etc., of the SSR switching ICs (2304), and comparing thosesamples to various thresholds (2306). These thresholds can includedigital thresholds, analog thresholds, frequency thresholds, expectedwaveforms, power thresholds, and so forth. Exceeding or violating thesethresholds can then trigger additional actions by the SSR switching ICor the thermostat processor.

For example, the method may include storing a sample history in thememory of the SSR switching IC to capture a sampled waveform surroundingthe threshold violation (2310). In this case, the SSR switching IC cancontinually monitor the waveforms, storing samples for only a briefperiod of time (e.g., 30-40 ms). When a threshold violation occurs, thestored samples captured before the violation can be saved, along with aninterval of samples captured after the violation. In embodiments wherethe SSR switching IC memory is relatively small, the samples can berepeatedly transferred to the secondary processor memory to therebystore a continuous stream of data that would otherwise be too large forthe SSR switching IC memory. In other embodiments, the samples can becontinuously saved as described above, but when a threshold violationoccurs, the sensor inputs can be sampled at a higher rate or stored at ahigher resolution to provide additional data surrounding the thresholdviolation.

The method may also include sending the sample history to the thermostatserver for fault analysis (2312). Instead of waiting for a nightlyupload, the samples in the time window surrounding the thresholdviolation can be uploaded to the thermostat server for analysis. Whilefault detection can result in an immediate output on the user interfaceof the thermostat, additional analysis can be performed at thethermostat server. For instance, the thermostat server can compare thewaveforms from a first thermostat with a library of waveforms for knowntypes of electrical faults. These waveforms can be used to diagnose whatwent wrong in a particular thermostat, and can then trigger a softwareupdate, a notification to the user, and/or other action by the server.

What is claimed is:
 1. A device comprising: a rectifier circuitproviding a rectified DC signal; a rechargeable energy-storage element;and a power-management integrated circuit (PMIC) comprising: a chargingcircuit for the rechargeable energy-storage element; a current-sensingcircuit that measures a current provided by the rectified DC signal; aprogrammable current limit; a voltage-sensing circuit that measures avoltage on the rechargeable energy-storage element; and a controllerthat regulates the current provided to a DC output of the PMIC based atleast in part on: the current provided by the rectified DC signal; theprogrammable current limit; and the voltage on the rechargeableenergy-storage element; wherein the DC output of the PMIC (i) providesenergy to a plurality of other energy-consuming subsystems on thedevice, and (ii) provides energy to the charging circuit for therechargeable energy-storage element.
 2. The device of claim 1, whereinthe DC output of the PMIC is coupled through an inductor to a storagecapacitor.
 3. The device of claim 1, wherein the controller regulatesthe current provided to the DC output by controlling a timing of avoltage applied to a gate of a transistor that is connected in seriesbetween the rectified DC signal and the DC output.
 4. The device ofclaim 3, wherein the timing of the voltage applied to the gate of thetransistor causes the transistor to act as a buck converter for the DCoutput.
 5. The device of claim 3, wherein the controller comprises apulse-width modulated (PWM) controller that regulates a pulse width ofthe voltage applied to the gate of the transistor.
 6. The device ofclaim 3, wherein the controller comprises a pulse-frequency modulation(PFM) controller or a constant on-time (COT) controller.
 7. The deviceof claim 1, wherein the plurality of other energy-consuming subsystemson the device comprises a plurality of DC/DC voltage converters.
 8. Thedevice of claim 1, wherein the controller causes the DC output toprovide at least a minimum voltage when the voltage on the rechargeableenergy-storage element falls below the minimum voltage.
 9. The device ofclaim 8, wherein the minimum voltage corresponds to a minimum requiredvoltage of at least one of the plurality of other energy-consumingsubsystems on the device.
 10. The device of claim 1, wherein thecontroller regulates the voltage of the DC output to be one voltage drophigher than a desired voltage on the rechargeable energy-storageelement.
 11. A method of powering a device, the method comprising:providing a rectified DC signal from a rectifier circuit to apower-management integrated circuit (PMIC); charging a rechargeableenergy-storage element using a charging circuit on the PMIC; measuring acurrent of the rectified DC signal provided by the rectified DC signalusing a current-sensing circuit on the PMIC; measuring a voltage on therechargeable energy-storage element using a voltage-sensing circuit onthe PMIC; regulating a current provided to a DC output of the PMIC usinga controller on the PMIC based at least in part on: the current providedby the rectified DC signal; a programmable current limit; and thevoltage on the rechargeable energy-storage element; providing energyfrom the DC output of the PMIC to a plurality of other energy-consumingsubsystems on the device; and providing energy from the DC output of thePMIC to the charging circuit for the rechargeable energy-storageelement.
 12. The method of claim 11, wherein the DC output of the PMICis coupled through an inductor to a storage capacitor.
 13. The method ofclaim 11, wherein the controller regulates the current provided to theDC output by controlling a timing of a voltage applied to a gate of atransistor that is connected in series between the rectified DC signaland the DC output.
 14. The method of claim 13, wherein the timing of thevoltage applied to the gate of the transistor causes the transistor toact as a buck converter for the DC output.
 15. The method of claim 13,wherein the controller comprises a pulse-width modulated (PWM)controller that regulates a pulse width of the voltage applied to thegate of the transistor.
 16. The method of claim 13, wherein thecontroller comprises a pulse-frequency modulation (PFM) controller or aconstant on-time (COT) controller.
 17. The method of claim 11, whereinthe plurality of other energy-consuming subsystems on the devicecomprises a plurality of DC/DC voltage converters.
 18. The method ofclaim 11, wherein the controller causes the DC output to provide atleast a minimum voltage when the voltage on the rechargeableenergy-storage element falls below the minimum voltage.
 19. The methodof claim 18, wherein the minimum voltage corresponds to a minimumrequired voltage of at least one of the plurality of otherenergy-consuming subsystems on the device.
 20. The method of claim 11,wherein the controller regulates the voltage of the DC output to be onevoltage drop higher than a desired voltage on the rechargeableenergy-storage element.